Controller KUKA Deutschland GmbH

KR C4 smallsize-2

Operating Instructions

KR C4 small-

size-2

Issued: 26.04.2018

Version: BA KR C4 smallsize-2 V7
 KR C4 smallsize-2

© Copyright 2018
KUKA Deutschland GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany

This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without
the express permission of KUKA Deutschland GmbH.
Other functions not described in this documentation may be operable in the controller. The user has
no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and software
described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to
guarantee total conformity. The information in this documentation is checked on a regular basis, how-
ever, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation

Publication: Pub BA KR C4 smallsize-2 (PDF) en

Book structure: BA KR C4 smallsize-2 V7.1
Version: BA KR C4 smallsize-2 V7

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 Contents

Contents
1 Introduction .................................................................................................. 7
1.1 Representation of warnings and notes ...................................................................... 7
1.2 Terms used ................................................................................................................ 7

2 Purpose ........................................................................................................ 9
2.1 Target group .............................................................................................................. 9
2.2 Intended use .............................................................................................................. 9

3 Product description ..................................................................................... 11

3.1 Overview of the robot controller ................................................................................. 11
3.2 Drive unit (Drive Configuration (DC)) ......................................................................... 12
3.3 Control PC ................................................................................................................. 12
3.3.1 Motherboard D3236-K interfaces .......................................................................... 13
3.3.2 Motherboard D3445-K interfaces .......................................................................... 14
3.4 Cabinet Control Unit, Small Robot ............................................................................. 15
3.5 Low-voltage power supply ......................................................................................... 16
3.6 Batteries ..................................................................................................................... 16
3.7 Bus systems and bus devices .................................................................................... 17
3.7.1 KUKA Controller Bus devices ............................................................................... 17
3.7.2 KUKA System Bus devices ................................................................................... 17
3.7.3 KUKA Extension Bus devices ............................................................................... 18
3.8 Cabinet cooling .......................................................................................................... 18
3.9 Space for integration of customer options ................................................................. 18
3.10 Transient limiter (optional) ......................................................................................... 19

4 Technical data .............................................................................................. 21

4.1 Cabinet Interface Board, Small Robot ....................................................................... 23
4.2 Space for integration of customer options ................................................................. 24
4.3 Dimensions ................................................................................................................ 24
4.4 Dimensions of boreholes for floor mounting .............................................................. 25
4.5 Installation conditions ................................................................................................. 25
4.6 Dimensions of the smartPAD holder (optional) .......................................................... 26
4.7 Plates and labels ........................................................................................................ 26
4.8 REACH duty to communicate information acc. to Art. 33 of Regulation (EC) 1907/2006 28

5 Safety ............................................................................................................ 29
5.1 General ...................................................................................................................... 29
5.1.1 Liability .................................................................................................................. 29
5.1.2 Intended use of the industrial robot ...................................................................... 29
5.1.3 EC declaration of conformity and declaration of incorporation ............................. 30
5.1.4 Terms used ........................................................................................................... 30
5.2 Personnel ................................................................................................................... 32
5.3 Workspace, safety zone and danger zone ................................................................. 33
5.3.1 Determining stopping distances ............................................................................ 33
5.4 Triggers for stop reactions ......................................................................................... 34
5.5 Safety functions ......................................................................................................... 34
5.5.1 Overview of the safety functions ........................................................................... 34
5.5.2 Safety controller .................................................................................................... 35

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 KR C4 smallsize-2

5.5.3 Selecting the operating mode ............................................................................... 35

5.5.4 “Operator safety” signal ........................................................................................ 36
5.5.5 EMERGENCY STOP device ................................................................................ 37
5.5.6 Logging off from the higher-level safety controller ................................................ 37
5.5.7 External EMERGENCY STOP device .................................................................. 38
5.5.8 Enabling device .................................................................................................... 38
5.5.9 External enabling device ...................................................................................... 39
5.5.10 External safe operational stop .............................................................................. 39
5.5.11 External safety stop 1 and external safety stop 2 ................................................. 39
5.5.12 Velocity monitoring in T1 ...................................................................................... 39
5.6 Additional protective equipment ................................................................................ 39
5.6.1 Jog mode .............................................................................................................. 39
5.6.2 Software limit switches ......................................................................................... 40
5.6.3 Mechanical end stops ........................................................................................... 40
5.6.4 Mechanical axis limitation (optional) ..................................................................... 40
5.6.5 Options for moving the manipulator without drive energy .................................... 40
5.6.6 Labeling on the industrial robot ............................................................................ 41
5.6.7 External safeguards ............................................................................................. 41
5.7 Overview of operating modes and safety functions ................................................... 42
5.8 Safety measures ........................................................................................................ 42
5.8.1 General safety measures ..................................................................................... 42
5.8.2 Transportation ...................................................................................................... 43
5.8.3 Start-up and recommissioning .............................................................................. 44
5.8.3.1 Checking machine data and safety configuration ............................................ 45
5.8.3.2 Start-up mode .................................................................................................. 47
5.8.4 Manual mode ........................................................................................................ 48
5.8.5 Simulation ............................................................................................................. 49
5.8.6 Automatic mode ................................................................................................... 49
5.8.7 Maintenance and repair ........................................................................................ 49
5.8.8 Decommissioning, storage and disposal .............................................................. 51
5.8.9 Safety measures for “single point of control” ........................................................ 51
5.9 Applied norms and regulations .................................................................................. 52

6 Planning ........................................................................................................ 55
6.1 Electromagnetic compatibility (EMC) ......................................................................... 55
6.2 Installation conditions ................................................................................................ 55
6.3 Connection conditions ............................................................................................... 55
6.4 Power supply connection via X1 Harting connector .................................................. 56
6.5 Overview of interfaces ............................................................................................... 56
6.5.1 Optional interfaces ............................................................................................... 57
6.6 Standard interfaces ................................................................................................... 57
6.6.1 Motor connector X20 ............................................................................................ 57
6.6.2 Safety interface .................................................................................................... 58
6.6.3 Description of safety interface X11 ....................................................................... 58
6.6.3.1 X11 connector contact diagram ....................................................................... 59
6.6.3.2 X11 safety interface ......................................................................................... 59
6.6.3.3 X11 external enabling switch ........................................................................... 61
6.6.3.4 Wiring example for E-STOP circuit and safeguard .......................................... 62
6.6.3.5 Wiring examples for safe inputs and outputs .................................................. 63

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6.6.4 X19 KUKA smartPAD ........................................................................................... 66

6.6.5 X21 RDC interface ................................................................................................ 66
6.6.6 X21 US2 RDC interface ........................................................................................ 67
6.6.7 Checking the US2 function, load voltage contactor .............................................. 68
6.7 Equipotential bonding ................................................................................................ 68
6.8 Performance level ...................................................................................................... 69
6.8.1 PFH values of the safety functions ....................................................................... 69

7 Transportation ............................................................................................. 71
7.1 Transportation using lifting tackle .............................................................................. 71
7.2 Transportation by pallet truck ..................................................................................... 72
7.3 Transportation with the set of rollers .......................................................................... 72

8 Start-up and recommissioning ................................................................... 73

8.1 Start-up ...................................................................................................................... 73
8.2 Installing the robot controller ...................................................................................... 73
8.3 Connecting the connecting cables ............................................................................. 73
8.4 Connecting the equipotential bonding (PE) ............................................................... 74
8.5 Reversing the battery discharge protection measures ............................................... 75
8.6 Power supply connection via X1 Harting connector ................................................... 75
8.7 Modifying the system configuration, exchanging devices .......................................... 76
8.8 Start-up mode ............................................................................................................ 76
8.9 Switching on the robot controller ................................................................................ 78

9 Operation ...................................................................................................... 79
9.1 KUKA smartPAD teach pendant ................................................................................ 79
9.1.1 Front view ............................................................................................................. 79
9.1.2 Rear view .............................................................................................................. 81

10 Maintenance ................................................................................................. 83
10.1 Maintenance symbols ................................................................................................ 83
10.2 Checking CCU_SR relay outputs ............................................................................... 84
10.3 Cleaning the robot controller ...................................................................................... 85

11 Repair ........................................................................................................... 87
11.1 Repair and procurement of spare parts ..................................................................... 87
11.2 Exchanging the external fan ...................................................................................... 87
11.2.1 Removing the external fan .................................................................................... 88
11.2.2 Installing the external fan ...................................................................................... 89
11.2.3 Concluding work ................................................................................................... 90
11.3 Exchanging the drive unit ........................................................................................... 90
11.3.1 Removing the drive unit ........................................................................................ 92
11.3.2 Installing the drive unit .......................................................................................... 92
11.3.3 Concluding work ................................................................................................... 93
11.4 Exchanging control PC components .......................................................................... 93
11.4.1 Exchanging the control PC ................................................................................... 93
11.4.1.1 Removing the control PC ................................................................................. 94
11.4.1.2 Installing the control PC ................................................................................... 95
11.4.1.3 Concluding work .............................................................................................. 95
11.4.2 PC fan ................................................................................................................... 96

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11.4.2.1 Removing the PC fan ...................................................................................... 96

11.4.2.2 Installing the PC fan ........................................................................................ 97
11.4.2.3 Concluding work .............................................................................................. 98
11.4.3 Exchanging the motherboard battery ................................................................... 98
11.4.4 Exchanging the motherboard ............................................................................... 98
11.4.5 Exchanging the SSD hard drive ........................................................................... 98
11.4.5.1 Removing the SSD hard drive ......................................................................... 99
11.4.5.2 Installing the SSD hard drive ........................................................................... 100
11.4.5.3 Concluding work .............................................................................................. 101
11.5 Exchanging the batteries ........................................................................................... 101
11.5.1 Removing the batteries ......................................................................................... 102
11.5.2 Installing the batteries .......................................................................................... 103
11.5.3 Concluding work ................................................................................................... 103
11.6 Exchanging the low-voltage power supply unit .......................................................... 103
11.6.1 Removing the low-voltage power supply unit ....................................................... 104
11.6.2 Installing the low-voltage power supply unit ......................................................... 105
11.6.3 Concluding work ................................................................................................... 106
11.7 Exchanging the mains filter ....................................................................................... 106
11.7.1 Removing the mains filter ..................................................................................... 107
11.7.2 Installing the mains filter ....................................................................................... 108
11.7.3 Concluding work ................................................................................................... 108
11.8 Exchanging the ballast resistor .................................................................................. 108
11.8.1 Removing the ballast resistor ............................................................................... 110
11.8.2 Installing the ballast resistor ................................................................................. 111
11.8.3 Concluding work ................................................................................................... 111
11.9 Exchanging CCUsr .................................................................................................... 111
11.9.1 Removing the CCUsr ............................................................................................ 112
11.9.2 Installing the CCUsr .............................................................................................. 114
11.9.3 Concluding work ................................................................................................... 115

12 Troubleshooting .......................................................................................... 117

12.1 LED display on Cabinet Control Unit, Small Robot ................................................... 117
12.2 Fuses on the Cabinet Control Unit, Small Robot ....................................................... 121

13 Decommissioning, storage and disposal .................................................. 123

13.1 Decommissioning ...................................................................................................... 123
13.2 Storage ...................................................................................................................... 123
13.3 Disposal ..................................................................................................................... 123

14 KUKA Service ............................................................................................... 125

14.1 Requesting support ................................................................................................... 125
14.2 KUKA Customer Support ........................................................................................... 125

Index ............................................................................................................. 133

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 1 Introduction

1 Introduction
t

1.1 Representation of warnings and notes

t

Safety These warnings are relevant to safety and must be observed.

These warnings mean that it is certain or highly probable

that death or severe injuries will occur, if no precautions
are taken.

These warnings mean that death or severe injuries may

occur, if no precautions are taken.

These warnings mean that minor injuries may occur, if

no precautions are taken.

These warnings mean that damage to property may oc-

cur, if no precautions are taken.

These warnings contain references to safety-relevant information or

general safety measures.
These warnings do not refer to individual hazards or individual pre-
cautionary measures.

This warning draws attention to procedures which serve to prevent or remedy

emergencies or malfunctions:

The following procedure must be followed exactly!

Procedures marked with this warning must be followed exactly.

Notices These notices serve to make your work easier or contain references to further
information.

Tip to make your work easier or reference to further information.

1.2 Terms used

Term Description
CIP Safety Common Industrial Protocol Safety
CIP Safety is an Ethernet/IP-based safety inter-
face for connecting a safety PLC to the robot
controller. (PLC = master, robot controller =
slave)
CCU_SR Cabinet Control Unit Small Robot
CIB_SR Cabinet Interface Board Small Robot
EDS Electronic Data Storage (memory card)
EMD Electronic Mastering Device
EMC Electromagnetic compatibility
KCB KUKA Controller Bus
KEB KUKA Extension Bus
KEI KUKA Extension Interface

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Term Description
KLI KUKA Line Interface. Connection to higher-level
control infrastructure (PLC, archiving)
KOI KUKA Option Interface
KONI KUKA Option Network Interface
KPC Control PC
KPP_SR KUKA Power Pack Small Robot
KRL KUKA robot programming language (KUKA
Robot Language)
KSB KUKA System Bus. Internal KUKA bus for inter-
nal networking of the controllers with each other
KSI KUKA Service Interface
KSP_SR KUKA Servo Pack Small Robot
KSS KUKA System Software
Manipulator The robot arm and the associated electrical
installations
PMB Power Management Board
RDC Resolver Digital Converter
SATA connections Data bus for exchanging data between the pro-
cessor and the hard drive
(Extended) SIB (Extended) Safety Interface Board
USB Universal Serial Bus. Bus system for connecting
additional devices to a computer
EA External axis (linear unit, Posiflex)

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 2 Purpose

2 Purpose
2

2.1 Target group

s

This documentation is aimed at users with the following knowledge and skills:
 Advanced knowledge of electrical and electronic systems
 Advanced knowledge of the robot controller
 Advanced knowledge of the Windows operating system

For optimal use of our products, we recommend that our customers

take part in a course of training at KUKA College. Information about
the training program can be found at www.kuka.com or can be ob-
tained directly from our subsidiaries.

2.2 Intended use

Use The robot controller is intended solely for operating the following components:
 KUKA industrial robots
 KUKA linear units
 KUKA positioners
An additional KR C4 smallsize drive box is required for operating external axes
(linear units, positioners).

Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. This includes e.g.:
 Use as a climbing aid
 Operation outside the permissible operating parameters
 Use in potentially explosive environments
 Use in underground mining

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 3 Product description

3 Product description

3.1
t
Overview of the robot controller

The robot controller consists of the following components:

s

Fig. 3-1: Overview of the robot controller (front)

1 Drive unit
2 Mains filter
3 Batteries
4 Cabinet Control Unit, Small Robot
5 Main switch
6 Safety Interface Board, Extended (optional)
7 Control PC

Fig. 3-2: Overview of the robot controller (rear)

1 Motor connector
2 External fan
3 Low-voltage power supply unit
4 Connection panel for options
5 Power supply connection X1
6 Ballast resistor
7 Data connector X21

The robot controller can optionally be equipped with a set of rollers. The set of
rollers enables the robot controller to be easily rolled out of and into a bank of
cabinets.

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3.2 Drive unit (Drive Configuration (DC))

Overview The drive unit consists of the following components:

Fig. 3-3: Overview of drive unit

1 Drive power supply KPP_SR400

2 Drive controller KSP_SR

Functions The drive unit performs the following functions:

 Generation of the intermediate circuit voltage
 Control of the motors
 Control of the brakes
 Checking of intermediate circuit voltage in braking mode

3.3 Control PC

Components The control PC (KPC) includes the following components:

 Motherboard
 Power supply unit
 Fan
 Processor
 Heat sink
 Memory modules
 Hard drive
 LAN Dual NIC network card
(not present on all motherboard variants)
 Optional modules, e.g. field bus cards

Functions The control PC (KPC) is responsible for the following functions of the robot
controller:
 Graphical user interface
 Program creation, correction, archiving, and maintenance
 Sequence control
 Path planning
 Control of the drive circuit
 Monitoring
 Safety equipment
 Communication with external periphery (other controllers, host computers,
PCs, network)

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 3 Product description

3.3.1 Motherboard D3236-K interfaces

Overview

Fig. 3-4: Motherboard D3236-K interfaces

1 Connector X961, power supply DC 24 V

2 Connector X962, PC fan
(optional, inside PC, depending on variant)
3 Field bus cards, slots 1 to 7
4 LAN Onboard – KUKA Controller Bus
5 LAN Onboard – KUKA System Bus
6 2 USB 2.0 ports
7 2 USB 3.0 ports
8 DVI-I
9 4 USB 2.0 ports
10 LAN Onboard – KUKA Option Network Interface
11 LAN Onboard – KUKA Line Interface

VGA support is possible via DVI on VGA adapter. The user interface
of the controller can only be displayed on an external monitor if no ac-
tive operator control device (smartPAD, VRP) is connected to the
controller.

KUKA Deutschland GmbH has assembled, tested and supplied the

motherboard with an optimum configuration. No liability will be ac-
cepted for modifications to the configuration that have not been car-
ried out by KUKA Deutschland GmbH.

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Slot assignment

Fig. 3-5: Slot assignment, motherboard D3236-K

Slot Type Plug-in card

1 PCI Field bus
2 PCI Field bus
3 - Not available
4 - Not available
5 - Not available
6 - Not available
7 - Not available

3.3.2 Motherboard D3445-K interfaces

Overview

Fig. 3-6: Motherboard D3445-K interfaces

1 Connector X961, power supply DC 24 V

2 Field bus cards, slots 1 to 7
3 LAN Onboard – KUKA Controller Bus
4 LAN Onboard – KUKA System Bus
5 2 USB 2.0 ports
6 2 USB 3.0 ports
7 DVI-D

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 3 Product description

8 Display port
9 4 USB 2.0 ports
10 LAN Onboard – KUKA Option Network Interface
11 LAN Onboard – KUKA Line Interface

VGA support is possible via DP on VGA adapter. The user interface

of the controller can only be displayed on an external monitor if no ac-
tive operator control device (smartPAD, VRP) is connected to the
controller.

KUKA Deutschland GmbH has assembled, tested and supplied the

motherboard with an optimum configuration. No liability will be ac-
cepted for modifications to the configuration that have not been car-
ried out by KUKA Deutschland GmbH.

Slot assignment

Fig. 3-7: Slot assignment, motherboard D3445-K

Slot Type Plug-in card

1 PCI Field bus
2 PCI Field bus
3 - not available
4 - not available
5 PCIe Not assigned
6 - not available
7 - not available

3.4 Cabinet Control Unit, Small Robot

Description The Cabinet Control Unit, Small Robot (CCU_SR) is the central power distrib-
utor and communication interface for all components of the robot controller.
The CCU_SR consists of the Cabinet Interface Board, Small Robot (CIB_SR)
and the Power Management Board (PMB). All data are transferred via this in-
ternal communication interface to the controller for further processing. If the
mains voltage fails, the control components continue to be powered by batter-
ies until the position data are saved and the controller has shut down. The
charge and quality of the batteries are checked by means of a load test.
The CCU_SR also incorporates sensing, control and switching functions. The
output signals are provided as electrically isolated outputs.

Functions  Communication interface for the components of the robot controller

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 Safe inputs and outputs

 Contactor activation
 4 floating outputs
 9 safe inputs
 smartPAD plugged in
 Mastering test
 6 Fast Measurement inputs for customer applications
 External fan monitoring
 Monitoring of power supply unit fan (if present)
 Temperature sensing:
 Control box internal temperature
 The following components are connected to the KPC via the KUKA Con-
troller Bus:
 Drive unit
 Resolver Digital Converter
 Digital I/O modules 8/8
 The following operator panels and service devices are connected to the
control PC via the KUKA System Bus:
 KUKA Operator Panel Interface
 Diagnostic LEDs
 Electronic Data Storage interface
Power supply with battery backup
 Drive unit
 External fan
 KUKA smartPAD
 Multi-core control PC
 Resolver Digital Converter (RDC)
Power supply without battery backup
 Motor brakes
 Customer interface

3.5 Low-voltage power supply

Description The low-voltage power supply unit provides power to the components of the
robot controller.
A green LED indicates the operating state of the low-voltage power supply
unit.

3.6 Batteries

Description In the event of a power failure, or if the power is switched off, the batteries en-
able the robot controller to be shut down in a controlled manner. The batteries
are charged via the CCU_SR and the charge is checked and indicated.

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 3 Product description

3.7 Bus systems and bus devices

Fig. 3-8: Bus systems

1 KUKA Service Interface KSI

2 KUKA Extension Bus KEB
3 KUKA Line Interface KLI
4 KUKA System Bus KSB
5 KUKA Controller Bus KCB

Further information:
KSI: Assembly and operating instructions “Optional interfaces for
KR C4 smallsize-2”
 KLI: Assembly and operating instructions “Optional interfaces for KR C4
smallsize-2”

3.7.1 KUKA Controller Bus devices

KCB devices The KCB includes the following devices:

 Drive unit
 Resolver Digital Converter (RDC)
 Controller Interface Board, Small Robot (CIB_SR)
 Electronic Mastering Device (EMD)

3.7.2 KUKA System Bus devices

KSB devices The KSB includes the following devices:

 CIB_SR SION
 smartPAD SION
 Extended SIB (optional)

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3.7.3 KUKA Extension Bus devices

Possible devices of the KUKA Extension Bus are described in the as-
sembly and operating instructions “Optional Interfaces”.

3.8 Cabinet cooling

Description The control cabinet is divided into two cooling circuits. The inner zone, con-
taining the control and power electronics, is cooled by the PC fan of the control
PC. In the outer zone, the ballast resistor, the low-voltage power supply unit
and the heat sinks of the drive unit are cooled directly with ambient air by the
external fan.

Upstream installation of filter mats at the ventilation slits

causes an increase in temperature, leading to a reduc-
tion in the service life of the installed devices!

Fig. 3-9: Cooling circuits

1 PC fan 3 Heat sink, low-voltage power

supply
2 External fan 4 Drive unit heat sink

3.9 Space for integration of customer options

Description The space for integration of customer options can be used for external cus-
tomer equipment, such as bus modules. It is located on the right-hand side of
the control cabinet and is designed as a top-hat rail. Depending on the cabinet
equipment, the top-hat rail may come completely or partially filled with pre-in-
stalled devices and components.
(>>> 4.2 "Space for integration of customer options" Page 24)

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 3 Product description

Fig. 3-10: Space for customer components

3.10 Transient limiter (optional)

Description The transient limiter is a surge voltage protector consisting of a base module
and a plugged-on protection module.

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 4 Technical data

4 Technical data
4

Basic data
KR C4 smallsize-2 RAL 7016
Maximum number of servo axes 6
t
Weight approx. 60 kg
Protection rating (IEC 60529) IP54
Sound level < 66 dB (A)
Default color Side panels: anthracite gray (RAL
7016);
Door: KUKA orange 2567
Load on cabinet roof 1500 N with even distribution
Clearance for side-by-side installa- 50 mm (with/without cooling unit)
tion

The controller is only longer supported from KSS version

≥ V8.3.20.

Power supply
If the robot controller is connected to a power system
connection without a grounded neutral or is operated with incorrect
machine data, this may cause malfunctions in the robot controller and mate-
rial damage to the power supply units. Electrical voltage can cause injuries.
The robot controller may only be operated with grounded-neutral power sup-
ply systems.

If no grounded neutral is available, or if the mains voltage differs from those

specified here, a transformer must be used.

Rated supply voltage AC 3x380 V, AC 3x400 V,

AC 3x440 V or AC 3x480 V
Direct connection with grounded
neutral
Rated supply voltage tolerance ±10%
Rated connected load 3.30 kVA
Short circuit current rating 5 kA
System impedance ≤ 300 mΩ
Ground leakage current -
Mains-side fusing 3x 32 A, slow-blowing
Mains-side fusing without drive box 3x 16 A, slow-blowing
Mains frequency 49 ... 61 Hz

Ambient condi- Ambient temperature during opera- +5 to +45 °C (278 K to 318 K)

tions tion
Ambient temperature during stor- -25 to +40 °C (248 K to 313 K)
age/transportation
Ambient temperature during stor- -25 to +70 °C (248 K to 343 K)
age/transportation without battery
Temperature change max. 1 K/min
Environmental conditions 3k3 acc. to DIN EN 60721-3-3:
1995
Altitude without derating up to 1000 m above mean sea level
Altitude with derating max. 1000 m ... 4000 m above
mean sea level (reduction in power
5%/1000 m)

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To prevent exhaustive discharge and thus destruction of

the batteries, the batteries must be recharged at regular
intervals according to the storage temperature.
If the storage temperature is +20 °C or lower, the batteries must be re-
charged every 9 months.
If the storage temperature is between +20 °C and +30 °C, the batteries must
be recharged every 6 months.
If the storage temperature is between +30 °C and +40 °C, the batteries must
be recharged every 3 months.

Vibration resis- r.m.s. acceleration (sustained oscillation)

tance During operation 0.1 g
During transportation 0.37 g
Frequency range (sustained oscillation)
During operation 4...120 Hz
During transportation 4...120 Hz
Acceleration (shock in X/Y/Z direction)
During operation 2.5 g
During transportation 10 g
Waveform/duration (shock in X/Y/Z direction)
During operation Half-sine/11 ms
During transportation Half-sine/11 ms

If more severe mechanical stress is expected, the controller must be installed

on anti-vibration components.

Control unit Supply voltage DC 27.1 V ± 0.1 V

Control PC Main processor See shipping version

DIMM memory modules See shipping version (min. 2 GB)
Hard drive See shipping version

KUKA smartPAD Supply voltage 20 … 27.1 V DC

Dimensions (WxHxD) approx. 24x29x5 cm3
Display Touch-sensitive color display
600 x 800 pixels
Display size 8.4"
Interfaces USB
Weight 1.1 kg
Protection rating (without USB stick IP 54
and USB connection closed with a
plug)

Cable lengths For cable designations, standard lengths and optional lengths, please refer to
the operating instructions or assembly instructions of the manipulator and/or
the assembly and operating instructions for KR C4 external cabling for robot
controllers.

When using smartPAD cable extensions, only two extensions may be

used. An overall cable length of 50 m must not be exceeded.

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The difference in the cable lengths between the individual channels

of the RDC box must not exceed 10 m.

4.1 Cabinet Interface Board, Small Robot

CIB_SR outputs Operating voltage, power ≤ 30 V

contacts
Current via power contact min. 10 mA
< 750 mA
Cable lengths (connection < 50 m cable lengths
of actuators)
< 100 m wire length (outgoing and incom-
ing lines)
Cable cross-section (con- ≥ 1 mm2
nection of actuators)
Switching cycles CIB_SR Service life: 20 years
< 100,000 (corresponds to 13 switching
cycles per day)

The module must be exchanged when the number of switching cycles is ex-
ceeded.

CIB_SR inputs Switching level of the inputs The state for the inputs is not defined for
the voltage range from 5 V to 11 V (transi-
tion range). Either the ON state or the OFF
state is set.
OFF state for the voltage range from -3 V to
5 V (OFF range).
ON state for the voltage range from 11 V to
30 V (ON range).
Load current with 24 V sup- > 10 mA
ply voltage
Load current with 18 V sup- > 6.5 mA
ply voltage
Max. load current < 15 mA
Cable length, terminal - < 50 m, or < 100 m wire length (outgoing
sensor and incoming lines)
Cable cross-section, test > 0.5 mm2
output - input connection
Capacitive load for the test < 200 nF
outputs per channel
Resistive load for the test < 33 Ω
outputs per channel

Test outputs A and B are sustained short-circuit proof.

The specified currents flow via the contact element connected to the
input. This must be rated for the maximum current of 15 mA.

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 KR C4 smallsize-2

4.2 Space for integration of customer options

Power dissipation of installed com- max. 20 W

ponents
Depth of installed components approx. 200 mm
Width 250 mm
Height 150 mm

4.3 Dimensions

Description The diagram (>>> Fig. 4-1 ) shows the dimensions of the robot controller in
conjunction with the optional drive box for operating external axes. If no exter-
nal axes are required, the robot controller stands on its own.

Fig. 4-1: Dimensions (in mm)

1 KR C4 smallsize drive box 2 KR C4 smallsize-2

(optional)

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 4 Technical data

Fig. 4-2: Dimensions with set of rollers (optional)

4.4 Dimensions of boreholes for floor mounting

The dimensions of the boreholes for floor mounting of the KR C4 smallsize-2

robot controller are shown below:

Fig. 4-3: Dimensions of boreholes for floor mounting (in mm)

Screw size: M8

4.5 Installation conditions

Description The following installation options are possible for the drive box:
 Stackable with up to 2 further KR C4 smallsize-2 robot controllers
 Stackable with the KR C4 smallsize drive box
 Side-by-side installation
 With set of rollers (not stackable)
The minimum clearances (>>> Fig. 4-4 ) must be observed, irrespective of
the installation type.

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 KR C4 smallsize-2

Fig. 4-4: Minimum clearances (in mm)

4.6 Dimensions of the smartPAD holder (optional)

The diagram (>>> Fig. 4-5 ) shows the dimensions and drilling locations for
mounting on the safety fence.

Fig. 4-5: Dimensions and drilling locations for smartPAD holder

4.7 Plates and labels

Overview The following plates and labels (>>> Fig. 4-6 ) are attached to the robot con-
troller. They must not be removed or rendered illegible. Illegible plates and la-
bels must be replaced.

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 4 Technical data

Fig. 4-6: Plates and labels

Item Description
1

Robot controller rating plate

2

Electric shock hazard

The operating instructions and safety regulations must be read and
understood before work is carried out on the robot controller.
3

Hot surface
During operation of the controller, surface temperatures may be
reached that could result in burn injuries. Protective gloves must be
worn!

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 KR C4 smallsize-2

Item Description
4

Crushing hazard
Installation of the rear panel poses a crushing hazard. Protective
gloves must be worn!
5

Control PC rating plate

The plates may vary slightly from the examples illustrated above de-
pending on the specific cabinet type or as a result of updates.

4.8 REACH duty to communicate information acc. to Art. 33 of Regulation (EC)

1907/2006

On the basis of the information provided by our suppliers, the following com-
ponents of this product contain substances included on the Candidate List of
Substances of Very High Concern (SVHCs) in a concentration exceeding 0.1
percent by mass. None of these substances are released under normal and
reasonably foreseeable conditions of use.

Product REACH candidate/SVHC substance name CAS number

CR 2032 button cell 1,2-Dimethoxyethane; Ethylene glycol dimethyl 110-71-4
ether (EGDME)

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 5 Safety

5 Safety
f

5.1 General
y

5.1.1 Liability

The device described in this document is either an industrial robot or a com-

ponent thereof.
Components of the industrial robot:
 Manipulator
 Robot controller
 Teach pendant
 Connecting cables
 External axes (optional)
e.g. linear unit, turn-tilt table, positioner
 Software
 Options, accessories
The industrial robot is built using state-of-the-art technology and in accor-
dance with the recognized safety rules. Nevertheless, misuse of the industrial
robot may constitute a risk to life and limb or cause damage to the industrial
robot and to other material property.
The industrial robot may only be used in perfect technical condition in accor-
dance with its designated use and only by safety-conscious persons who are
fully aware of the risks involved in its operation. Use of the industrial robot is
subject to compliance with this document and with the declaration of incorpo-
ration supplied together with the industrial robot. Any functional disorders af-
fecting safety must be rectified immediately.

Safety infor- Information about safety may not be construed against KUKA Deutschland
mation GmbH. Even if all safety instructions are followed, this is not a guarantee that
the industrial robot will not cause personal injuries or material damage.
No modifications may be carried out to the industrial robot without the autho-
rization of KUKA Deutschland GmbH. Additional components (tools, software,
etc.), not supplied by KUKA Deutschland GmbH, may be integrated into the
industrial robot. The user is liable for any damage these components may
cause to the industrial robot or to other material property.
In addition to the Safety chapter, this document contains further safety instruc-
tions. These must also be observed.

5.1.2 Intended use of the industrial robot

The industrial robot is intended exclusively for the use designated in the “Pur-
pose” chapter of the operating instructions or assembly instructions.
Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. The manufacturer is not liable for any damage resulting
from such misuse. The risk lies entirely with the user.
Operation of the industrial robot in accordance with its intended use also re-
quires compliance with the operating and assembly instructions for the individ-
ual components, with particular reference to the maintenance specifications.

Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. This includes e.g.:

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 Use as a climbing aid

 Operation outside the specified operating parameters
 Operation without the required safety equipment

5.1.3 EC declaration of conformity and declaration of incorporation

The industrial robot constitutes partly completed machinery as defined by the

EC Machinery Directive. The industrial robot may only be put into operation if
the following preconditions are met:
 The industrial robot is integrated into a complete system.
or: The industrial robot, together with other machinery, constitutes a com-
plete system.
or: All safety functions and safeguards required for operation in the com-
plete machine as defined by the EC Machinery Directive have been added
to the industrial robot.
 The complete system complies with the EC Machinery Directive. This has
been confirmed by means of a conformity assessment procedure.

EC declaration of The system integrator must issue an EC declaration of conformity for the com-
conformity plete system in accordance with the Machinery Directive. The EC declaration
of conformity forms the basis for the CE mark for the system. The industrial
robot must always be operated in accordance with the applicable national
laws, regulations and standards.
The robot controller has a CE mark in accordance with the EMC Directive and
the Low Voltage Directive.

Declaration of The partly completed machinery is supplied with a declaration of incorporation

incorporation in accordance with Annex II B of the EC Machinery Directive 2006/42/EC. The
assembly instructions and a list of essential requirements complied with in ac-
cordance with Annex I are integral parts of this declaration of incorporation.
The declaration of incorporation declares that the start-up of the partly com-
pleted machinery is not allowed until the partly completed machinery has been
incorporated into machinery, or has been assembled with other parts to form
machinery, and this machinery complies with the terms of the EC Machinery
Directive, and the EC declaration of conformity is present in accordance with
Annex II A.

5.1.4 Terms used

STOP 0, STOP 1 and STOP 2 are the stop definitions according to EN 60204-
1:2006.

Term Description
Axis range Range of each axis, in degrees or millimeters, within which it may move.
The axis range must be defined for each axis.
Stopping distance Stopping distance = reaction distance + braking distance
The stopping distance is part of the danger zone.
Workspace Area within which the robot may move. The workspace is derived from
the individual axis ranges.
User The user of the industrial robot can be the management, employer or
delegated person responsible for use of the industrial robot.
Danger zone The danger zone consists of the workspace and the stopping distances
of the manipulator and external axes (optional).

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Term Description
Service life The service life of a safety-relevant component begins at the time of
delivery of the component to the customer.
The service life is not affected by whether the component is used or not,
as safety-relevant components are also subject to aging during storage.
KUKA smartPAD see “smartPAD”
Manipulator The robot arm and the associated electrical installations
Safety zone The safety zone is situated outside the danger zone.
Safe operational stop The safe operational stop is a standstill monitoring function. It does not
stop the robot motion, but monitors whether the robot axes are station-
ary. If these are moved during the safe operational stop, a safety stop
STOP 0 is triggered.
The safe operational stop can also be triggered externally.
When a safe operational stop is triggered, the robot controller sets an
output to the field bus. The output is set even if not all the axes were sta-
tionary at the time of triggering, thereby causing a safety stop STOP 0 to
be triggered.
Safety STOP 0 A stop that is triggered and executed by the safety controller. The safety
controller immediately switches off the drives and the power supply to
the brakes.
Note: This stop is called safety STOP 0 in this document.
Safety STOP 1 A stop that is triggered and monitored by the safety controller. The brak-
ing operation is carried out by the non-safety-oriented section of the
robot controller and monitored by the safety controller. As soon as the
manipulator has stopped, the safety controller deactivates the drives
and the power supply of the brakes.
When a safety STOP 1 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 1 can also be triggered externally.
Note: This stop is called safety STOP 1 in this document.
Safety STOP 2 A stop that is triggered and monitored by the safety controller. The brak-
ing operation is carried out by the non-safety-oriented section of the
robot controller and monitored by the safety controller. The drives
remain activated and the brakes released. As soon as the manipulator is
at a standstill, a safe operational stop is triggered.
When a safety STOP 2 is triggered, the robot controller sets an output to
the field bus.
The safety STOP 2 can also be triggered externally.
Note: This stop is called safety STOP 2 in this document.
Safety options Generic term for options which make it possible to configure additional
safe monitoring functions in addition to the standard safety functions.
Example: SafeOperation
smartPAD Programming device for the robot controller
The smartPAD has all the operator control and display functions
required for operating and programming the industrial robot.
Stop category 0 The drives are deactivated immediately and the brakes are applied. The
manipulator and any external axes (optional) perform path-oriented
braking.
Note: This stop category is called STOP 0 in this document.

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Term Description
Stop category 1 The manipulator and any external axes (optional) perform path-main-
taining braking.
 Operating mode T1: The drives are deactivated as soon as the robot
has stopped, but no later than after 680 ms.
 Operating modes T2, AUT (KR C4), AUT EXT (KR C4), EXT
(VKR C4):
The drives are switched off after 1.5 s.
Note: This stop category is called STOP 1 in this document.
Stop category 1 - The manipulator and any external axes (optional) perform path-oriented
Drive Ramp Stop braking.
 Operating mode T1: The drives are deactivated as soon as the robot
has stopped, but no later than after 680 ms.
 Operating modes T2, AUT (KR C4), AUT EXT (KR C4), EXT
(VKR C4):
The drives are switched off after 1.5 s.
Note: This stop category is called STOP 1 - DRS in this document.
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a path-
maintaining braking ramp.
Note: This stop category is called STOP 2 in this document.
System integrator The system integrator is responsible for safely integrating the industrial
(plant integrator) robot into a complete system and commissioning it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Axis of motion that does not belong to the manipulator, yet is controlled
with the robot controller. e.g. KUKA linear unit, turn-tilt table, Posiflex

5.2 Personnel

The following persons or groups of persons are defined for the industrial robot:
 User
 Personnel

All persons working with the industrial robot must have read and un-
derstood the industrial robot documentation, including the safety
chapter.

User The user must observe the labor laws and regulations. This includes e.g.:
 The user must comply with his monitoring obligations.
 The user must carry out briefing at defined intervals.

Personnel Personnel must be instructed, before any work is commenced, in the type of
work involved and what exactly it entails as well as any hazards which may ex-
ist. Instruction must be carried out regularly. Instruction is also required after
particular incidents or technical modifications.
Personnel includes:
 System integrator
 Operators, subdivided into:
 Start-up, maintenance and service personnel
 Operating personnel

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 Cleaning personnel

Installation, exchange, adjustment, operation, maintenance and re-

pair must be performed only as specified in the operating or assembly
instructions for the relevant component of the industrial robot and only
by personnel specially trained for this purpose.

System integrator The industrial robot is safely integrated into a complete system by the system
integrator.
The system integrator is responsible for the following tasks:
 Installing the industrial robot
 Connecting the industrial robot
 Performing risk assessment
 Implementing the required safety functions and safeguards
 Issuing the EC declaration of conformity
 Attaching the CE mark
 Creating the operating instructions for the system

Operators The operator must meet the following preconditions:

 The operator must be trained for the work to be carried out.
 Work on the system must only be carried out by qualified personnel. These
are people who, due to their specialist training, knowledge and experi-
ence, and their familiarization with the relevant standards, are able to as-
sess the work to be carried out and detect any potential hazards.

Work on the electrical and mechanical equipment of the industrial ro-

bot may only be carried out by specially trained personnel.

5.3 Workspace, safety zone and danger zone

Workspaces are to be restricted to the necessary minimum size. A workspace

must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone. In
the case of a stop, the manipulator and external axes (optional) are braked
and come to a stop within the danger zone.
The danger zone consists of the workspace and the stopping distances of the
manipulator and external axes (optional). It must be safeguarded by means of
physical safeguards to prevent danger to persons or the risk of material dam-
age.

5.3.1 Determining stopping distances

The system integrator’s risk assessment may indicate that the stopping dis-
tances must be determined for an application. In order to determine the stop-
ping distances, the system integrator must identify the safety-relevant points
on the programmed path.
When determining the stopping distances, the robot must be moved with the
tool and loads which are also used in the application. The robot must be at op-
erating temperature. This is the case after approx. 1 h in normal operation.
During execution of the application, the robot must be stopped at the point
from which the stopping distance is to be calculated. This process must be re-
peated several times with a safety stop 0 and a safety stop 1. The least favor-
able stopping distance is decisive.

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A safety stop 0 can be triggered by a safe operational stop via the safety inter-
face, for example. If a safety option is installed, it can be triggered, for in-
stance, by a space violation (e.g. the robot exceeds the limit of an activated
workspace in Automatic mode).
A safety stop 1 can be triggered by pressing the EMERGENCY STOP device
on the smartPAD, for example.

5.4 Triggers for stop reactions

Stop reactions of the industrial robot are triggered in response to operator ac-
tions or as a reaction to monitoring functions and error messages. The follow-
ing table shows the different stop reactions according to the operating mode
that has been set.

Trigger T1, T2 AUT, AUT EXT

Start key released STOP 2 -
STOP key pressed STOP 2
Drives OFF STOP 1
$MOVE_ENABLE input STOP 2
drops out
Power switched off via STOP 0
main switch or power fail-
ure
Internal error in non- STOP 0 or STOP 1
safety-oriented part of the
(dependent on the cause of the error)
robot controller
Operating mode changed Safety stop 2
during operation
Safety gate opened (oper- - Safety stop 1
ator safety)
Enabling switch released Safety stop 2 -
Enabling switch pressed Safety stop 1 -
fully down or error
E-STOP pressed Safety stop 1
Error in safety controller Safety stop 0
or periphery of the safety
controller

5.5 Safety functions

5.5.1 Overview of the safety functions

The following safety functions are present in the industrial robot:

 Selecting the operating mode
 Operator safety (= connection for the monitoring of physical safeguards)
 EMERGENCY STOP device
 Enabling device
 External safe operational stop
 External safety stop 1
 External safety stop 2
 Velocity monitoring in T1
The safety functions of the industrial robot meet the following requirements:

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 Category 3 and Performance Level d in accordance with EN ISO 13849-

1
The requirements are only met on the following condition, however:
 The EMERGENCY STOP device is pressed at least once every 12
months.
The following components are involved in the safety functions:
 Safety controller in the control PC
 KUKA smartPAD
 Cabinet Control Unit (CCU)
 Resolver Digital Converter (RDC)
 KUKA Power Pack (KPP)
 KUKA Servo Pack (KSP)
 Safety Interface Board (SIB) (if used)
There are also interfaces to components outside the industrial robot and to
other robot controllers.

In the absence of operational safety functions and safe-

guards, the industrial robot can cause personal injury or
material damage. If safety functions or safeguards are dismantled or deacti-
vated, the industrial robot may not be operated.

During system planning, the safety functions of the overall system

must also be planned and designed. The industrial robot must be in-
tegrated into this safety system of the overall system.

5.5.2 Safety controller

The safety controller is a unit inside the control PC. It links safety-relevant sig-
nals and safety-relevant monitoring functions.
Safety controller tasks:
 Switching off the drives; applying the brakes
 Monitoring the braking ramp
 Standstill monitoring (after the stop)
 Velocity monitoring in T1
 Evaluation of safety-relevant signals
 Setting of safety-oriented outputs

5.5.3 Selecting the operating mode

Operating modes The industrial robot can be operated in the following modes:
 Manual Reduced Velocity (T1)
 Manual High Velocity (T2)
 Automatic (AUT)
 Automatic External (AUT EXT)

Do not change the operating mode while a program is running. If the

operating mode is changed during program execution, the industrial
robot is stopped with a safety stop 2.

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Operat-
Use Velocities
ing mode
 Program verification:
Programmed velocity, maxi-
For test operation, pro- mum 250 mm/s
T1 gramming and teach-
ing  Jog mode:
Jog velocity, maximum
250 mm/s
 Program verification:
T2 For test operation Programmed velocity
 Jog mode: Not possible
For industrial robots  Program operation:
AUT without higher-level Programmed velocity
controllers  Jog mode: Not possible
For industrial robots  Program operation:
AUT EXT with higher-level con- Programmed velocity
trollers, e.g. PLC  Jog mode: Not possible

Mode selector The user can change the operating mode via the connection manager. The
switch connection manager is a view that is called by means of the mode selector
switch on the smartPAD.
The mode selector switch may be one of the following variants:
 With key
It is only possible to change operating mode if the key is inserted.
 Without key

If the smartPAD is fitted with a switch without a key:

An additional device must be present to ensure that the
relevant functions cannot be executed by all users, but only by a restricted
group of people.
The device itself must not trigger motions of the industrial robot or other haz-
ards. If this device is missing, death or severe injuries may result.

The system integrator is responsible for ensuring that such a device is imple-
mented.

5.5.4 “Operator safety” signal

The “operator safety” signal is used for monitoring physical safeguards, e.g.
safety gates. Automatic operation is not possible without this signal. In the
event of a loss of signal during automatic operation (e.g. safety gate is
opened), the manipulator stops with a safety stop 1.
Operator safety is not active in modes T1 (Manual Reduced Velocity) and T2
(Manual High Velocity).

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Following a loss of signal, automatic operation may only

be resumed when the safeguard has been closed and
when the closing has been acknowledged. This acknowledgement is to pre-
vent automatic operation from being resumed inadvertently while there are
still persons in the danger zone, e.g. due to the safety gate closing acciden-
tally.
The acknowledgement must be designed in such a way that an actual check
of the danger zone can be carried out first. Other acknowledgement functions
(e.g. an acknowlegement which is automatically triggered by closure of the
safeguard) are not permitted.
The system integrator is responsible for ensuring that these criteria are met.
Failure to met them may result in death, severe injuries or considerable dam-
age to property.

5.5.5 EMERGENCY STOP device

The EMERGENCY STOP device for the industrial robot is the EMERGENCY
STOP device on the smartPAD. The device must be pressed in the event of a
hazardous situation or emergency.
Reactions of the industrial robot if the EMERGENCY STOP device is pressed:
 The manipulator and any external axes (optional) are stopped with a safe-
ty stop 1.
Before operation can be resumed, the EMERGENCY STOP device must be
turned to release it.

Tools and other equipment connected to the robot must

be integrated into the EMERGENCY STOP circuit on the
system side if they could constitute a potential hazard.
Failure to observe this precaution may result in death, severe injuries or con-
siderable damage to property.

There must always be at least one external EMERGENCY STOP device in-
stalled. This ensures that an EMERGENCY STOP device is available even
when the smartPAD is disconnected.
(>>> 5.5.7 "External EMERGENCY STOP device" Page 38)

5.5.6 Logging off from the higher-level safety controller

If the robot controller is connected to a higher-level safety controller, this con-

nection will inevitably be terminated in the following cases:
 Switching off the voltage via the main switch of the robot
Or power failure
 Shutdown of the robot controller via the smartHMI
 Activation of a WorkVisual project in WorkVisual or directly on the robot
controller
 Changes to Start-up > Network configuration
 Changes to Configuration > Safety configuration
 I/O drivers > Reconfigure
 Restoration of an archive
Effect of the interruption:
 If a discrete safety interface is used, this triggers an EMERGENCY STOP
for the overall system.

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 If the Ethernet interface is used, the KUKA safety controller generates a

signal that prevents the higher-level controller from triggering an EMER-
GENCY STOP for the overall system.

If the Ethernet safety interface is used: In his risk assessment, the

system integrator must take into consideration whether the fact that
switching off the robot controller does not trigger an EMERGENCY
STOP of the overall system could constitute a hazard and, if so, how this haz-
ard can be countered.
Failure to take this into consideration may result in death, injuries or damage
to property.

If a robot controller is switched off, the E-STOP device on

the smartPAD is no longer functional. The user is re-
sponsible for ensuring that the smartPAD is either covered or removed from
the system. This serves to prevent operational and non-operational EMER-
GENCY STOP devices from becoming interchanged.
Failure to observe this precaution may result in death, injuries or damage to
property.

5.5.7 External EMERGENCY STOP device

Every operator station that can initiate a robot motion or other potentially haz-
ardous situation must be equipped with an EMERGENCY STOP device. The
system integrator is responsible for ensuring this.
There must always be at least one external EMERGENCY STOP device in-
stalled. This ensures that an EMERGENCY STOP device is available even
when the smartPAD is disconnected.
External EMERGENCY STOP devices are connected via the customer inter-
face. External EMERGENCY STOP devices are not included in the scope of
supply of the industrial robot.

5.5.8 Enabling device

The enabling devices of the industrial robot are the enabling switches on the
smartPAD.
There are 3 enabling switches installed on the smartPAD. The enabling
switches have 3 positions:
 Not pressed
 Center position
 Panic position
In the test modes, the manipulator can only be moved if one of the enabling
switches is held in the central position.
 Releasing the enabling switch triggers a safety stop 2.
 Pressing the enabling switch down fully (panic position) triggers a safety
stop 1.
 It is possible to hold 2 enabling switches in the center position simultane-
ously for up to 15 seconds. This makes it possible to adjust grip from one
enabling switch to another one. If 2 enabling switches are held simultane-
ously in the center position for longer than 15 seconds, this triggers a safe-
ty stop 1.
If an enabling switch malfunctions (e.g. jams in the central position), the indus-
trial robot can be stopped using the following methods:
 Press the enabling switch down fully.

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 Actuate the EMERGENCY STOP device.

 Release the Start key.

The enabling switches must not be held down by adhe-

sive tape or other means or tampered with in any other
way.
Death, injuries or damage to property may result.

5.5.9 External enabling device

External enabling devices are required if it is necessary for more than one per-
son to be in the danger zone of the industrial robot.
External enabling devices are not included in the scope of supply of the indus-
trial robot.

Which interface can be used for connecting external enabling devices

is described in the “Planning” chapter of the robot controller operating
instructions and assembly instructions.

5.5.10 External safe operational stop

The safe operational stop can be triggered via an input on the customer inter-
face. The state is maintained as long as the external signal is FALSE. If the
external signal is TRUE, the manipulator can be moved again. No acknowl-
edgement is required.

5.5.11 External safety stop 1 and external safety stop 2

Safety stop 1 and safety stop 2 can be triggered via an input on the customer
interface. The state is maintained as long as the external signal is FALSE. If
the external signal is TRUE, the manipulator can be moved again. No ac-
knowledgement is required.
If interface X11 is selected as the customer interface, only the signal Safety
stop 2 is available.

5.5.12 Velocity monitoring in T1

The velocity at the mounting flange is monitored in T1 mode. If the velocity ex-
ceeds 250 mm/s, a safety stop 0 is triggered.

5.6 Additional protective equipment

5.6.1 Jog mode

In the operating modes T1 (Manual Reduced Velocity) and T2 (Manual High

Velocity), the robot controller can only execute programs in jog mode. This
means that it is necessary to hold down an enabling switch and the Start key
in order to execute a program.
 Releasing the enabling switch triggers a safety stop 2.
 Pressing the enabling switch down fully (panic position) triggers a safety
stop 1.
 Releasing the Start key triggers a STOP 2.

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5.6.2 Software limit switches

The axis ranges of all manipulator and positioner axes are limited by means of
adjustable software limit switches. These software limit switches only serve as
machine protection and must be adjusted in such a way that the manipula-
tor/positioner cannot hit the mechanical end stops.
The software limit switches are set during commissioning of an industrial ro-
bot.

Further information is contained in the operating and programming in-

structions.

5.6.3 Mechanical end stops

Depending on the robot variant, the axis ranges of the main and wrist axes of
the manipulator are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.

If the manipulator or an external axis hits an obstruction

or a mechanical end stop or mechanical axis limitation,
the manipulator can no longer be operated safely. The manipulator must be
taken out of operation and KUKA Deutschland GmbH must be consulted be-
fore it is put back into operation.

5.6.4 Mechanical axis limitation (optional)

Some manipulators can be fitted with mechanical axis limitation systems in

axes A1 to A3. The axis limitation systems restrict the working range to the re-
quired minimum. This increases personal safety and protection of the system.
In the case of manipulators that are not designed to be fitted with mechanical
axis limitation, the workspace must be laid out in such a way that there is no
danger to persons or material property, even in the absence of mechanical
axis limitation.
If this is not possible, the workspace must be limited by means of photoelectric
barriers, photoelectric curtains or obstacles on the system side. There must be
no shearing or crushing hazards at the loading and transfer areas.

This option is not available for all robot models. Information on spe-
cific robot models can be obtained from KUKA Deutschland GmbH.

5.6.5 Options for moving the manipulator without drive energy

The system user is responsible for ensuring that the training of per-
sonnel with regard to the response to emergencies or exceptional sit-
uations also includes how the manipulator can be moved without
drive energy.

Description The following options are available for moving the manipulator without drive
energy after an accident or malfunction:
 Release device (optional)
The release device can be used for the main axis drive motors and, de-
pending on the robot variant, also for the wrist axis drive motors.

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 Brake release device (option)

The brake release device is designed for robot variants whose motors are
not freely accessible.
 Moving the wrist axes directly by hand
There is no release device available for the wrist axes of variants in the low
payload category. This is not necessary because the wrist axes can be
moved directly by hand.

Information about the options available for the various robot models
and about how to use them can be found in the assembly and oper-
ating instructions for the robot or requested from KUKA Deutschland
GmbH.

Moving the manipulator without drive energy can dam-

age the motor brakes of the axes concerned. The motor
must be replaced if the brake has been damaged. The manipulator may
therefore be moved without drive energy only in emergencies, e.g. for rescu-
ing persons.

5.6.6 Labeling on the industrial robot

All plates, labels, symbols and marks constitute safety-relevant parts of the in-
dustrial robot. They must not be modified or removed.
Labeling on the industrial robot consists of:
 Identification plates
 Warning signs
 Safety symbols
 Designation labels
 Cable markings
 Rating plates

Further information is contained in the technical data of the operating

instructions or assembly instructions of the components of the indus-
trial robot.

5.6.7 External safeguards

The access of persons to the danger zone of the industrial robot must be pre-
vented by means of safeguards. It is the responsibility of the system integrator
to ensure this.
Physical safeguards must meet the following requirements:
 They meet the requirements of EN ISO 14120.
 They prevent access of persons to the danger zone and cannot be easily
circumvented.
 They are sufficiently fastened and can withstand all forces that are likely
to occur in the course of operation, whether from inside or outside the en-
closure.
 They do not, themselves, represent a hazard or potential hazard.
 Prescribed clearances, e.g. to danger zones, are adhered to.
Safety gates (maintenance gates) must meet the following requirements:
 They are reduced to an absolute minimum.

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 The interlocks (e.g. safety gate switches) are linked to the operator safety
input of the robot controller via safety gate switching devices or safety
PLC.
 Switching devices, switches and the type of switching conform to the re-
quirements of Performance Level d and category 3 according to
EN ISO 13849-1.
 Depending on the risk situation: the safety gate is additionally safeguarded
by means of a locking mechanism that only allows the gate to be opened
if the manipulator is safely at a standstill.
 The button for acknowledging the safety gate is located outside the space
limited by the safeguards.

Further information is contained in the corresponding standards and

regulations. These also include EN ISO 14120.

Other safety Other safety equipment must be integrated into the system in accordance with
equipment the corresponding standards and regulations.

5.7 Overview of operating modes and safety functions

The following table indicates the operating modes in which the safety functions
are active.

Safety functions T1 T2 AUT AUT EXT

Operator safety - - Active Active
EMERGENCY STOP device Active Active Active Active
Enabling device Active Active - -
Reduced velocity during pro-
Active - - -
gram verification
Jog mode Active Active - -
Software limit switches Active Active Active Active

5.8 Safety measures

5.8.1 General safety measures

The industrial robot may only be used in perfect technical condition in accor-
dance with its intended use and only by safety-conscious persons. Operator
errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial robot
even after the robot controller has been switched off and locked out. Incorrect
installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause
the manipulator or external axes to sag. If work is to be carried out on a
switched-off industrial robot, the manipulator and external axes must first be
moved into a position in which they are unable to move on their own, whether
the payload is mounted or not. If this is not possible, the manipulator and ex-
ternal axes must be secured by appropriate means.

In the absence of operational safety functions and safe-

guards, the industrial robot can cause personal injury or
material damage. If safety functions or safeguards are dismantled or deacti-
vated, the industrial robot may not be operated.

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Standing underneath the robot arm can cause death or

injuries. For this reason, standing underneath the robot
arm is prohibited!

The motors reach temperatures during operation which

can cause burns to the skin. Contact must be avoided.
Appropriate safety precautions must be taken, e.g. protective gloves must be
worn.

smartPAD The user must ensure that the industrial robot is only operated with the smart-
PAD by authorized persons.
If more than one smartPAD is used in the overall system, it must be ensured
that it is clearly recognizable which smartPAD is connected to which industrial
robot. They must not be interchanged.

The operator must ensure that decoupled smartPADs

are immediately removed from the system and stored out
of sight and reach of personnel working on the industrial robot. This serves
to prevent operational and non-operational EMERGENCY STOP devices
from becoming interchanged.
Failure to observe this precaution may result in death, severe injuries or con-
siderable damage to property.

Modifications After modifications to the industrial robot, checks must be carried out to ensure
the required safety level. The valid national or regional work safety regulations
must be observed for this check. The correct functioning of all safety functions
must also be tested.
New or modified programs must always be tested first in Manual Reduced Ve-
locity mode (T1).
After modifications to the industrial robot, existing programs must always be
tested first in Manual Reduced Velocity mode (T1). This applies to all compo-
nents of the industrial robot and includes e.g. modifications of the external
axes or to the software and configuration settings.

Faults The following tasks must be carried out in the case of faults in the industrial
robot:
 Switch off the robot controller and secure it (e.g. with a padlock) to prevent
unauthorized persons from switching it on again.
 Indicate the fault by means of a label with a corresponding warning (tag-
out).
 Keep a record of the faults.
 Eliminate the fault and carry out a function test.

5.8.2 Transportation

Manipulator The prescribed transport position of the manipulator must be observed. Trans-
portation must be carried out in accordance with the operating instructions or
assembly instructions of the robot.
Avoid vibrations and impacts during transportation in order to prevent damage
to the manipulator.

Robot controller The prescribed transport position of the robot controller must be observed.
Transportation must be carried out in accordance with the operating instruc-
tions or assembly instructions of the robot controller.

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Avoid vibrations and impacts during transportation in order to prevent damage

to the robot controller.

External axis The prescribed transport position of the external axis (e.g. KUKA linear unit,
(optional) turn-tilt table, positioner) must be observed. Transportation must be carried
out in accordance with the operating instructions or assembly instructions of
the external axis.

5.8.3 Start-up and recommissioning

Before starting up systems and devices for the first time, a check must be car-
ried out to ensure that the systems and devices are complete and operational,
that they can be operated safely and that any damage is detected.
The valid national or regional work safety regulations must be observed for this
check. The correct functioning of all safety functions must also be tested.

The passwords for the user groups must be changed in the KUKA
System Software before start-up. The passwords must only be com-
municated to authorized personnel.

The robot controller is preconfigured for the specific in-

dustrial robot. If cables are interchanged, the manipula-
tor and the external axes (optional) may receive incorrect data and can thus
cause personal injury or material damage. If a system consists of more than
one manipulator, always connect the connecting cables to the manipulators
and their corresponding robot controllers.

If additional components (e.g. cables), which are not part of the scope
of supply of KUKA Deutschland GmbH, are integrated into the indus-
trial robot, the user is responsible for ensuring that these components
do not adversely affect or disable safety functions.

If the internal cabinet temperature of the robot controller

differs greatly from the ambient temperature, condensa-
tion can form, which may cause damage to the electrical components. Do not
put the robot controller into operation until the internal temperature of the
cabinet has adjusted to the ambient temperature.

Function test The following tests must be carried out before start-up and recommissioning:
General test:
It must be ensured that:
 The industrial robot is correctly installed and fastened in accordance with
the specifications in the documentation.
 There is no damage to the robot that could be attributed to external forces.
Examples: Dents or abrasion that could be caused by an impact or colli-
sion.

In the case of such damage, the affected components

must be exchanged. In particular, the motor and counter-
balancing system must be checked carefully.
External forces can cause non-visible damage. For example, it can lead to
a gradual loss of drive power from the motor, resulting in unintended move-
ments of the manipulator. Death, injuries or considerable damage to property
may otherwise result.

 There are no foreign bodies or loose parts on the industrial robot.

 All required safety equipment is correctly installed and operational.

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 The power supply ratings of the industrial robot correspond to the local
supply voltage and mains type.
 The ground conductor and the equipotential bonding cable are sufficiently
rated and correctly connected.
 The connecting cables are correctly connected and the connectors are
locked.
Test of the safety functions:
A function test must be carried out for the following safety functions to ensure
that they are functioning correctly:
 Local EMERGENCY STOP device
 External EMERGENCY STOP device (input and output)
 Enabling device (in the test modes)
 Operator safety
 All other safety-relevant inputs and outputs used
 Other external safety functions

5.8.3.1 Checking machine data and safety configuration

The industrial robot must not be moved if incorrect ma-

chine data or an incorrect controller configuration are
loaded. Death, severe injuries or considerable damage to property may oth-
erwise result. The correct data must be loaded.

 Following the start-up procedure, the practical tests for the machine data
must be carried out. The tool must be calibrated (either via an actual cali-
bration or through numerical entry of the data).
 Following modifications to the machine data, the safety configuration must
be checked.
 After activation of a WorkVisual project on the robot controller, the safety
configuration must be checked.
 If machine data are adopted when checking the safety configuration (re-
gardless of the reason for the safety configuration check), the practical
tests for the machine data must be carried out.
 System Software 8.3 or higher: If the checksum of the safety configuration
has changed, the safe axis monitoring functions must be checked.

Information about checking the safety configuration and the safe axis
monitoring functions is contained in the Operating and Programming
Instructions for System Integrators.

If the practical tests are not successfully completed in the initial start-up, KUKA
Deutschland GmbH must be contacted.
If the practical tests are not successfully completed during a different proce-
dure, the machine data and the safety-relevant controller configuration must
be checked and corrected.

General practical If practical tests are required for the machine data, this test must always be
test carried out.
For 6-axis robots:
The following methods are available for performing the practical test:
 TCP calibration with the XYZ 4-point method
The practical test is passed if the TCP has been successfully calibrated.
Or:

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1. Align the TCP with a freely selected point. The point serves as a reference
point.
 The point must be located so that reorientation is possible.
 The point must not be located on the Z axis of the FLANGE coordinate
system.
2. Move the TCP manually at least 45° once in each of the A, B and C direc-
tions.
The movements do not have to be accumulative, i.e. after motion in one
direction it is possible to return to the original position before moving in the
next direction.
The practical test is passed if the TCP does not deviate from the reference
point by more than 2 cm in total.
For palletizing robots:
Palletizing robots, in this case, are either robots that can be used only as pal-
letizers from the start or robots operated in palletizing mode. The latter must
also be in palletizing mode during the practical test.
First part:
1. Mark the starting position of the TCP.
Also read and note the starting position from the Actual position – Car-
tesian display on the smartHMI.
2. Jog the TCP in the X direction. The distance must be at least 20% of the
robot’s maximum reach. Determine the exact length via the Actual posi-
tion display.
3. Measure the distance covered and compare it with the distance value dis-
played on the smartHMI. The deviation must be < 5%.
4. Repeat steps 1 and 2 for the Y direction and Z direction.
The first part of the practical test is passed if the deviation is < 5% in every di-
rection.
Second part:
 Rotate the tool manually about A by 45°: once in the plus direction, once
in the minus direction. At the same time, observe the TCP.
The second part of the practical test is passed if the position of the TCP in
space is not altered during the rotations.

Practical test for If practical tests are required for the machine data, this test must be carried out
axes that are not when axes are present that are not mathematically coupled.
mathematically 1. Mark the starting position of the axis that is not mathematically coupled.
coupled Also read and note the start position from the Actual position display on
the smartHMI.
2. Move the axis manually by a freely selected path length. Determine the
path length from the Actual position display.
 Move linear axes a specific distance.
 Move rotational axes through a specific angle.
3. Measure the length of the path covered and compare it with the value dis-
played on the smartHMI.
The practical test is passed if the values differ by no more than 5%.
4. Repeat the test for each axis that is not mathematically coupled.

Practical test for If practical tests are required for the machine data, this test must be carried out
robot on KUKA if the robot and KL are mathematically coupled.
linear unit  Move the KL manually in Cartesian mode.
The practical test is passed if the TCP does not move at the same time.

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Practical test for If practical tests are required for the machine data, this test must be carried out
couplable axes when axes are present that can be physically coupled and uncoupled, e.g. a
servo gun.
1. Physically uncouple the couplable axis.
2. Move all the remaining axes individually.
The practical test is passed if it has been possible to move all the remain-
ing axes.

5.8.3.2 Start-up mode

Description The industrial robot can be set to Start-up mode via the smartHMI user inter-
face. In this mode, the manipulator can be moved in T1 without the external
safeguards being put into operation.
The safety interface used affects “Start-up” mode:
Discrete safety interface
 System Software 8.2 or earlier:
Start-up mode is always possible if all input signals at the discrete safety
interface have the state “logic zero”. If this is not the case, the robot con-
troller prevents or terminates Start-up mode.
If an additional discrete safety interface for safety options is used, the in-
puts there must also have the state “logic zero”.
 System Software 8.3 or higher:
Start-up mode is always possible. This also means that it is independent
of the state of the inputs at the discrete safety interface.
If an additional discrete safety interface is used for safety options: The
states of these inputs are also irrelevant.
Ethernet safety interface
The robot controller prevents or terminates Start-up mode if a connection to a
higher-level safety system exists or is established.

Effect When the Start-up mode is activated, all outputs are automatically set to the
state “logic zero”.
If the robot controller has a peripheral contactor (US2), and if the safety con-
figuration specifies for this to switch in accordance with the motion enable,
then the same also applies in Start-up mode. This means that if motion enable
is present, the US2 voltage is switched on – even in Start-up mode.

The maximum number of switching cycles of the periph-

eral contactors is 175 per day.

Hazards Possible hazards and risks involved in using Start-up mode:

 A person walks into the manipulator’s danger zone.
 In a hazardous situation, a disabled external EMERGENCY STOP device
is actuated and the manipulator is not shut down.
Additional measures for avoiding risks in Start-up mode:
 Cover disabled EMERGENCY STOP devices or attach a warning sign in-
dicating that the EMERGENCY STOP device is out of operation.
 If there is no safety fence, other measures must be taken to prevent per-
sons from entering the manipulator’s danger zone, e.g. use of warning
tape.

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Use Intended use of Start-up mode:

 Start-up in T1 mode when the external safeguards have not yet been in-
stalled or put into operation. The danger zone must be delimited at least
by means of warning tape.
 Fault localization (periphery fault).
 Use of Start-up mode must be minimized as much as possible.

Use of Start-up mode disables all external safeguards.

The service personnel are responsible for ensuring that
there is no-one in or near the danger zone of the manipulator as long as the
safeguards are disabled.
Failure to observe this precaution may result in death, injuries or damage to
property.

Misuse Any use or application deviating from the intended use is deemed to be misuse
and is not allowed. KUKA Deutschland GmbH is not liable for any damage re-
sulting from such misuse. The risk lies entirely with the user.

5.8.4 Manual mode

General Manual mode is the mode for setup work. Setup work is all the tasks that have
to be carried out on the industrial robot to enable automatic operation. Setup
work includes:
 Jog mode
 Teaching
 Programming
 Program verification
The following must be taken into consideration in manual mode:
 New or modified programs must always be tested first in Manual Reduced
Velocity mode (T1).
 The manipulator, tooling or external axes (optional) must never touch or
project beyond the safety fence.
 Workpieces, tooling and other objects must not become jammed as a re-
sult of the industrial robot motion, nor must they lead to short-circuits or be
liable to fall off.
 All setup work must be carried out, where possible, from outside the safe-
guarded area.

Setup work in T1 If it is necessary to carry out setup work from inside the safeguarded area, the
following must be taken into consideration in the operating mode Manual Re-
duced Velocity (T1):
 If it can be avoided, there must be no other persons inside the safeguard-
ed area.
 If it is necessary for there to be several persons inside the safeguarded ar-
ea, the following must be observed:
 Each person must have an enabling device.
 All persons must have an unimpeded view of the industrial robot.
 Eye-contact between all persons must be possible at all times.
 The operator must be so positioned that he can see into the danger area
and get out of harm’s way.
 Unexpected motions of the manipulator cannot be ruled out, e.g. in the
event of a fault. For this reason, an appropriate clearance must be main-

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tained between persons and the manipulator (including tool). Guide value:
50 cm.
The minimum clearance may vary depending on local circumstances, the
motion program and other factors. The minimum clearance that is to apply
for the specific application must be decided by the user on the basis of a
risk assessment.

Setup work in T2 If it is necessary to carry out setup work from inside the safeguarded area, the
following must be taken into consideration in the operating mode Manual High
Velocity (T2):
 This mode may only be used if the application requires a test at a velocity
higher than that possible in T1 mode.
 Teaching and programming are not permissible in this operating mode.
 Before commencing the test, the operator must ensure that the enabling
devices are operational.
 The operator must be positioned outside the danger zone.
 There must be no other persons inside the safeguarded area. It is the re-
sponsibility of the operator to ensure this.

5.8.5 Simulation

Simulation programs do not correspond exactly to reality. Robot programs cre-

ated in simulation programs must be tested in the system in Manual Reduced
Velocity mode (T1). It may be necessary to modify the program.

5.8.6 Automatic mode

Automatic mode is only permissible in compliance with the following safety

measures:
 All safety equipment and safeguards are present and operational.
 There are no persons in the system.
 The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for no ap-
parent reason, the danger zone must not be entered until an EMERGENCY
STOP has been triggered.

5.8.7 Maintenance and repair

After maintenance and repair work, checks must be carried out to ensure the
required safety level. The valid national or regional work safety regulations
must be observed for this check. The correct functioning of all safety functions
must also be tested.
The purpose of maintenance and repair work is to ensure that the system is
kept operational or, in the event of a fault, to return the system to an operation-
al state. Repair work includes troubleshooting in addition to the actual repair
itself.
The following safety measures must be carried out when working on the indus-
trial robot:
 Carry out work outside the danger zone. If work inside the danger zone is
necessary, the user must define additional safety measures to ensure the
safe protection of personnel.
 Switch off the industrial robot and secure it (e.g. with a padlock) to prevent
it from being switched on again. If it is necessary to carry out work with the

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robot controller switched on, the user must define additional safety mea-
sures to ensure the safe protection of personnel.
 If it is necessary to carry out work with the robot controller switched on, this
may only be done in operating mode T1.
 Label the system with a sign indicating that work is in progress. This sign
must remain in place, even during temporary interruptions to the work.
 The EMERGENCY STOP devices must remain active. If safety functions
or safeguards are deactivated during maintenance or repair work, they
must be reactivated immediately after the work is completed.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again. The system must then be checked to en-
sure that it is deenergized.
It is not sufficient, before commencing work on live parts, to execute an
EMERGENCY STOP or a safety stop, or to switch off the drives, as this does
not disconnect the robot system from the mains power supply. Parts remain
energized. Death or severe injuries may result.

Faulty components must be replaced using new components with the same
article numbers or equivalent components approved by KUKA Deutschland
GmbH for this purpose.
Cleaning and preventive maintenance work is to be carried out in accordance
with the operating instructions.

Robot controller Even when the robot controller is switched off, parts connected to peripheral
devices may still carry voltage. The external power sources must therefore be
switched off if work is to be carried out on the robot controller.
The ESD regulations must be adhered to when working on components in the
robot controller.
Voltages in excess of 50 V (up to 780 V) can be present in various compo-
nents for several minutes after the robot controller has been switched off! To
prevent life-threatening injuries, no work may be carried out on the industrial
robot in this time.
Water and dust must be prevented from entering the robot controller.

Counterbal- Some robot variants are equipped with a hydropneumatic, spring or gas cylin-
ancing system der counterbalancing system.
The hydropneumatic and gas cylinder counterbalancing systems are pressure
equipment and, as such, are subject to obligatory equipment monitoring and
the provisions of the Pressure Equipment Directive.
The user must comply with the applicable national laws, regulations and stan-
dards pertaining to pressure equipment.
Inspection intervals in Germany in accordance with Industrial Safety Order,
Sections 14 and 15. Inspection by the user before commissioning at the instal-
lation site.
The following safety measures must be carried out when working on the coun-
terbalancing system:
 The manipulator assemblies supported by the counterbalancing systems
must be secured.
 Work on the counterbalancing systems must only be carried out by quali-
fied personnel.

Hazardous The following safety measures must be carried out when handling hazardous
substances substances:
 Avoid prolonged and repeated intensive contact with the skin.

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 Avoid breathing in oil spray or vapors.

 Clean skin and apply skin cream.

To ensure safe use of our products, we recommend regularly re-

questing up-to-date safety data sheets for hazardous substances.

5.8.8 Decommissioning, storage and disposal

The industrial robot must be decommissioned, stored and disposed of in ac-

cordance with the applicable national laws, regulations and standards.

5.8.9 Safety measures for “single point of control”

Overview If certain components in the industrial robot are operated, safety measures
must be taken to ensure complete implementation of the principle of “single
point of control” (SPOC).
The relevant components are:
 Submit interpreter
 PLC
 OPC server
 Remote control tools
 Tools for configuration of bus systems with online functionality
 KUKA.RobotSensorInterface

The implementation of additional safety measures may be required.

This must be clarified for each specific application; this is the respon-
sibility of the system integrator, programmer or user of the system.

Since only the system integrator knows the safe states of actuators in the pe-
riphery of the robot controller, it is his task to set these actuators to a safe
state, e.g. in the event of an EMERGENCY STOP.

T1, T2 In modes T1 and T2, the components referred to above may only access the
industrial robot if the following signals have the following states:

Signal State required for SPOC

$USER_SAF TRUE
$SPOC_MOTION_ENABLE TRUE

Submit inter- If motions, (e.g. drives or grippers) are controlled with the submit interpreter or
preter, PLC the PLC via the I/O system, and if they are not safeguarded by other means,
then this control will take effect even in T1 and T2 modes or while an EMER-
GENCY STOP is active.
If variables that affect the robot motion (e.g. override) are modified with the
submit interpreter or the PLC, this takes effect even in T1 and T2 modes or
while an EMERGENCY STOP is active.
Safety measures:
 In T1 and T2, the system variable $OV_PRO must not be written to by the
submit interpreter or the PLC.
 Do not modify safety-relevant signals and variables (e.g. operating mode,
EMERGENCY STOP, safety gate contact) via the submit interpreter or
PLC.
If modifications are nonetheless required, all safety-relevant signals and
variables must be linked in such a way that they cannot be set to a dan-

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gerous state by the submit interpreter or PLC. This is the responsibility of

the system integrator.

OPC server, These components can be used with write access to modify programs, outputs
remote control or other parameters of the robot controller, without this being noticed by any
tools persons located inside the system.
Safety measure:
If these components are used, outputs that could cause a hazard must be de-
termined in a risk assessment. These outputs must be designed in such a way
that they cannot be set without being enabled. This can be done using an ex-
ternal enabling device, for example.

Tools for configu- If these components have an online functionality, they can be used with write
ration of bus access to modify programs, outputs or other parameters of the robot control-
systems ler, without this being noticed by any persons located inside the system.
 WorkVisual from KUKA
 Tools from other manufacturers
Safety measure:
In the test modes, programs, outputs or other parameters of the robot control-
ler must not be modified using these components.

5.9 Applied norms and regulations

Name/Edition Definition

2006/42/EU:2006 Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Council
of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast)

2014/30/EU:2014 EMC Directive:

Directive 2014/30/EC of the European Parliament and of the Council
dated 26 February 2014 on the approximation of the laws of the
Member States concerning electromagnetic compatibility

2014/68/EU:2014 Pressure Equipment Directive:

Directive 2014/68/EU of the European Parliament and of the Council
dated 15 May 2014 on the approximation of the laws of the Member
States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbalancing
system.)

EN ISO 13850:2015 Safety of machinery:

Emergency stop - Principles for design

EN ISO 13849-1:2015 Safety of machinery:

Safety-related parts of control systems - Part 1: General principles of
design

EN ISO 13849-2:2012 Safety of machinery:

Safety-related parts of control systems - Part 2: Validation

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EN ISO 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction

EN ISO 10218-1:2011 Industrial robots – Safety requirements:

Part 1: Robots
Note: Content equivalent to ANSI/RIA R.15.06-2012, Part 1

EN 614- Safety of machinery:

1:2006+A1:2009
Ergonomic design principles - Part 1: Terms and general principles

EN 61000-6-2:2005 Electromagnetic compatibility (EMC):

Part 6-2: Generic standards; Immunity for industrial environments

EN 61000-6-4:2007 + Electromagnetic compatibility (EMC):

A1:2011
Part 6-4: Generic standards; Emission standard for industrial envi-
ronments

EN 60204- Safety of machinery:

1:2006/A1:2009
Electrical equipment of machines - Part 1: General requirements

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6.1 Electromagnetic compatibility (EMC)

Description If connecting cables (e.g. field buses, etc.) are routed to the control PC from
outside, only shielded cables with an adequate degree of shielding may be
used. The cable shield must be connected with maximum surface area to the
PE rail in the cabinet using shield terminals (screw-type, no clamps).

The robot controller corresponds to EMC class A, Group 1, in accor-

dance with EN 55011 and is intended for use in an industrial setting.
Assuring the electromagnetic compatibility in other environments
may be difficult due to conducted and radiated disturbances that are liable to
occur.

6.2 Installation conditions

The dimensions and installation conditions of the robot controller are specified
in the section “Technical data”.
(>>> 4.3 "Dimensions" Page 24)
(>>> 4.5 "Installation conditions" Page 25)

6.3 Connection conditions

Technical data Technical data of the power supply connection: (>>> 4 "Technical data"
Page 21)

If the robot controller is connected to a power system

without a grounded neutral, this may cause malfunc-
tions in the robot controller and material damage to the power supply units.
Electrical voltage can cause injuries. The robot controller may only be oper-
ated with grounded-neutral power supply systems.

If the robot controller is operated with a supply voltage

other than that specified on the rating plate, this may
cause malfunctions in the robot controller and material damage to the power
supply units. The robot controller may only be operated with the supply volt-
age specified on the rating plate.

The appropriate machine data must be loaded in accordance with the

rated supply voltage.

If use of a residual-current circuit-breaker (RCCB) is planned, we rec-

ommend the following RCCB: trip current difference 300 mA per robot
controller, universal-current sensitive, selective.

Cable lengths For cable designations, standard lengths and optional lengths, please refer to
the operating instructions or assembly instructions of the manipulator and/or
the assembly and operating instructions for KR C4 external cabling for robot
controllers.

When using smartPAD cable extensions, only two extensions may be

used. An overall cable length of 50 m must not be exceeded.

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The difference in the cable lengths between the individual channels

of the RDC box must not exceed 10 m.

6.4 Power supply connection via X1 Harting connector

Description A Harting connector bypack is supplied with the robot controller. The customer
can connect the robot controller to the power supply via connector X1.

If the robot controller is connected to a rated supply voltage greater

than 400 V without a transformer, the power cable to X1 must be
shielded. The shield must be connected to ground on at least one
side.

Fig. 6-1: Power supply connection X1

1 Harting connector bypack (optional)

2 Power supply connection X1

6.5 Overview of interfaces

Overview The robot controller is equipped with the following cables as standard:
 Device connection cable
 Motor cable, data cable
 smartPAD cable
 Peripheral cables
Peripheral/bus cables depending on the customer variant and/or options are
connected to the connection panel for options.

Interfaces

Fig. 6-2: Overview of interfaces

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1 Service interface X69

2 USB 3.0 interface
3 Connection panel for options
4 Power supply connection
5 smartPAD interface X19
6 Data interface X21
7 Reference switch X42, mastering test
8 Interface X21.1, 2nd RDC
9 Motor connector X20

Representation The connector pin allocation is represented in tabular form. Pins that are not
assigned are not listed here.

The connector bypacks required for terminating the connectors are

available from KUKA Deutschland GmbH as an accessory pack.

6.5.1 Optional interfaces

The optional interfaces are described in the assembly and operating

instructions “Optional Interfaces”.

All contactor, relay and valve coils that are connected to the robot
controller by the user must be equipped with suitable suppressor di-
odes. RC elements and VCR resistors are not suitable.

6.6 Standard interfaces

6.6.1 Motor connector X20

Description The motors and brakes of the robot axes are connected to the robot controller
via motor connector X20.

Necessary  Harting Han-Yellock monoblock, size 30

equipment

Fig. 6-3: Contact diagram, view from contact side

Motor connector
Pin Description
X20
1 Motor M1 U1
6 Motor M1 V1
11 Motor M1 W1
2 Motor M2 U1
7 Motor M2 V1
12 Motor M2 W1

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Pin Description
3 Motor M3 U1
8 Motor M3 V1
13 Motor M3 W1
4 Motor M4 U1
9 Motor M4 V1
14 Motor M4 W1
5 Motor M5 U1
10 Motor M5 V1
15 Motor M5 W1
21 Motor M6 U1
22 Motor M6 V1
23 Motor M6 W1
18 Brake, axes 1-3, 24 V
24 Brake, axes 1-3, GND
19 Brake, axes 4-6, 24 V
25 Brake, axes 4-6, GND
20 PE

6.6.2 Safety interface

Description EMERGENCY STOP devices must be connected via a safety interface or

linked together by means of higher-level controllers (e.g. PLCs).
Take the following points into consideration when wiring the safety interface:
 System concept
 Safety concept

Safety interfaces The following safety interfaces are available:

 X13 parallel safety, Safe Robot
 X66 Ethernet safety interface (PROFIsafe, CIP Safety)
 X55 / X67.1 / X67.2 Ethernet safety interface (FSoE)

The optional interfaces are described in the assembly and operating

instructions “Optional Interfaces”.

6.6.3 Description of safety interface X11

Description EMERGENCY STOP devices must be connected via safety interface X11 or
linked together by means of higher-level controllers (e.g. PLC).

Wiring Take the following points into consideration when wiring safety interface X11:
 System concept
 Safety concept

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6.6.3.1 X11 connector contact diagram

Contact diagram,
connector X11

Fig. 6-4: Contact diagram

 X11, mating connector: Han 108DD with a male insert

 Housing size: 24B
 Cable gland M32
 Cable diameter 14-21 mm
 Cable cross-section ≥ 1 mm2

In the cabling for the input signals and test signals in the system, suit-
able measures must be taken to prevent a cross-connection between
the voltages (e.g. separate cabling of input signals and test signals).

In the cabling for the output signals and test signals in the system,
suitable measures must be taken to prevent a cross-connection be-
tween the output signals of a channel (e.g. separate cabling).

6.6.3.2 X11 safety interface

The X11 safety interface is wired internally to the CCU_SR.

Connector pin
Pin Description Function
allocation X11
1 CIB_SR test output A Makes the pulsed voltage avail-
3 able for the individual interface
(test signal)
inputs of channel A.
5
7 These signals may only be
mapped with the safe inputs of
9
channel A.
19 CIB_SR test output B Makes the clocked voltage
21 available for the individual
(test signal)
interface inputs of channel B.
23
25 These signals may only be
mapped with the safe inputs of
27
channel B.
8 Safe operational stop, channel Safe operational stop input for
A all axes
26 Safe operational stop, channel Activation of standstill monitor-
B ing
Stop 0 is initiated if the acti-
vated monitoring is violated.
10 Safety stop 2, channel A Safety stop 2 input for all axes
28 Safety stop 2, channel B Triggering of stop 2 and activa-
tion of standstill monitoring at
standstill of all axes.
Stop 0 is initiated if the acti-
vated monitoring is violated.

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Pin Description Function

37 Local E-STOP channel A Output, floating contacts from
38 internal E-STOP
(>>> "CIB_SR outputs"
55 Local E-STOP channel B
Page 23)
56
The contacts are closed if the
following conditions are met:
 E-STOP on smartPAD not
actuated
 Controller switched on and
operational
The contacts open if any condi-
tion is not met.
2 External E-STOP channel A Dual-channel E-STOP input
20 External E-STOP channel B (>>> "CIB_SR inputs"
Page 23)
Triggering of the E-STOP func-
tion in the robot controller.
6 Acknowledge operator safety, For connection of a dual-chan-
channel A nel input for acknowledging
24 Acknowledge operator safety, operator safety with floating
channel B contacts (>>> "CIB_SR
inputs" Page 23)
The response of the “Operator
safety acknowledgement” input
can be configured in the KUKA
system software.
After closing the safety gate
(operator safety), manipulator
motion can be enabled in the
automatic modes using an
acknowledge button outside
the safety fence. This function
is deactivated on delivery.
4 Operator safety, channel A For dual-channel connection of
22 Operator safety, channel B a safety gate locking mecha-
nism (>>> "CIB_SR inputs"
Page 23)
As long as the signal is active,
the drives can be switched on.
Only effective in the AUTO-
MATIC modes.
41 Peri enabled, channel A Output, floating contact
42 (>>> "CIB_SR outputs"
Page 23)
59 Peri enabled, channel B
60 (>>> "Signal “Peri enabled”
(PE)" Page 61)

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Pin Description Function

39 Acknowledge operator safety, Output, floating contact for
40 channel A operator safety acknowledge-
ment (>>> "CIB_SR outputs"
57 Acknowledge operator safety,
Page 23)
58 channel B
Output can be used to forward
the assured operator safety
(input BS = 1 and, if configured,
input QBS acknowledged) to
other robot controllers on the
same safety fence.

Signal “Peri The signal “Peri enabled” is set to 1 (active) if the following conditions are met:
enabled” (PE)  Drives are switched on.
 Safety controller motion enable signal present.
 The message “Operator safety open” must not be active.
This message is not active in the modes T1 and T2.
“Peri enabled” in conjunction with the signal “Safe operational stop”
 In the case of activation of the signal “Safe operational stop” during the
motion:
 Error -> braking with Stop 0. “Peri enabled” eliminated.
 Activation of the signal “Safe operational stop” with the manipulator sta-
tionary:
Release the brakes, switch drives to servo-control and monitor for restart.
“Peri enabled” remains active.
 Signal “Motion enable” remains active.
 US2 voltage (if present) remains active.
 Signal “Peri enabled” remains active.
“Peri enabled” in conjunction with the signal “Safety stop 2”
 In the case of activation of the signal “Safety stop 2”:
 Stop 2 of the manipulator.
 Signal “Drive enable” remains active.
 Brakes remain released.
 Manipulator remains under servo-control.
 Monitoring for restart active.
 Signal “Motion enable” is deactivated.
 US2 voltage (if present) is deactivated.
 Signal “Peri enabled” is deactivated.

6.6.3.3 X11 external enabling switch

Description External enabling switches can be connected to the robot controller via inter-
face X11.

Connector pin
Pin Description Function
allocation X11
11 CCU_SR test output A Makes the pulsed voltage avail-
13 able for the individual interface
(test signal)
inputs of channel A.
These signals may only be
mapped with the CCU_SR.

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Pin Description Function

29 CCU_SR test output B Makes the clocked voltage
31 available for the individual
(test signal)
interface inputs of channel B.
These signals may only be
mapped with the CCU_SR.
12 External enabling 1 channel A For connection of an external
30 External enabling 1 channel B 2-channel enabling switch 1
with floating contacts.
If no external enabling switch 1
is connected, channel A pins
11/12 and channel B 29/30
must be jumpered. Only effec-
tive in TEST modes.
(>>> "Function of external axis
enabling switch" Page 62)
14 External enabling 2 channel A For connection of an external
32 External enabling 2 channel B 2-channel enabling switch 2
with floating contacts.
If no external enabling switch 2
is connected, channel A pins
13/14 and channel B 31/32
must be jumpered. Only effec-
tive in TEST modes.
(>>> "Function of external axis
enabling switch" Page 62)

Function of  External enabling 1

external axis Enabling switch must be pressed for jogging in T1 or T2. Input is closed.
enabling switch  External enabling 2
Enabling switch is not in the panic position. Input is closed.
 If a smartPAD is connected, its enabling switches and the external en-
abling are ANDed.

Function External External

Switch position
(only active for T1 and T2) enabling 1 enabling 2

Safety stop 1 (drives switched off Input open Input open No operational
when axis at standstill) state
Safety stop 2 (safe operational stop, Input open Input closed Not pressed
drives switched on)
Safety stop 1 (drives switched off Input closed Input open Panic position
when axis at standstill)
Axes enabled (axis jogging possible) Input closed Input closed Center position

6.6.3.4 Wiring example for E-STOP circuit and safeguard

Description The EMERGENCY STOP devices are connected to X11 in the robot control-
ler.

EMERGENCY
The EMERGENCY STOP devices on the robot controller
STOP must be integrated into the EMERGENCY STOP circuit
of the system by the system integrator.
Failure to do this may result in death, severe injuries or considerable damage
to property.

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Fig. 6-5: Wiring example: EMERGENCY STOP

Safety gate A dual-channel acknowledge button must be installed outside the physical
safeguard. The closing of the safety gate must be confirmed by pressing the
acknowledge button before the industrial robot can be started again in Auto-
matic mode.

The safety gate on the robot controller must be integrat-

ed into the safeguard circuit of the system by the system
integrator.
Failure to do this may result in death, severe injuries or considerable damage
to property.

Fig. 6-6: Wiring example: Operator safety with safety gate

6.6.3.5 Wiring examples for safe inputs and outputs

Safe input The switch-off capability of the inputs is monitored cyclically.

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The inputs of the SIB are of dual-channel design with external testing. The
dual-channel operation of the inputs is monitored cyclically.
The following diagram illustrates the connection of a safe input to a floating
contact provided by the customer.

Fig. 6-7: Connection schematic for safe input

1 Safe input, SIB

2 SIB/CIB
3 Robot controller
4 Interface X11 or X13
5 Test output channel B
6 Test output channel A
7 Input X, channel A
8 Input X, channel B
9 System side
10 Floating contact

Test outputs A and B are fed with the supply voltage of the SIB. Test outputs
A and B are sustained short-circuit proof. The test outputs must only be used
to supply the SIB inputs, and for no other purpose.
The wiring example described can be used to achieve compliance with Cate-
gory 3 and Performance Level (PL) d according to EN ISO 13849-1.

Dynamic testing  The switch-off capability of the inputs is tested cyclically. For this, the test
outputs TA_A and TA_B are switched off alternately.
 The switch-off pulse length is defined for the SIBs as t1 = 625 μs (125 μs
– 2.375 ms).
 The duration t2 between two switch-off pulses on one channel is 106 ms.
 The input channel SIN_x_A must be supplied by the test signal TA_A. The
input channel SIN_x_B must be supplied by the test signal TA_B. No other
power supply is permissible.
 It is only permitted to connect sensors which allow the connection of test
signals and which provide floating contacts.
 The signals TA_A and TA_B must not be significantly delayed by the
switching element.

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Switch-off pulse
diagram

Fig. 6-8: Switch-off pulse diagram, test outputs

t1 Switch-off pulse length

t2 Switch-off period per channel (106 ms)
t3 Offset between switch-off pulses of both channels (53 ms)
TA/A Test output channel A
TA/B Test output channel B
SIN_X_A Input X, channel A
SIN_X_B Input X, channel B

Safe output On the SIB, the outputs are provided as dual-channel floating relay outputs.
The following diagram illustrates the connection of a safe output to a safe input
provided by the customer with external test facility. The input used by the cus-
tomer must be monitored externally for cross-connection.

Fig. 6-9: Connection schematic for safe output

1 SIB
2 Robot controller
3 Interface X11 or X13
4 Output wiring
5 System side
6 Safe input (Fail Safe PLC, safety switching device)
7 Test output channel B
8 Test output channel A
9 Input X, channel A
10 Input X, channel B

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The wiring example described can be used to achieve compliance with Cate-
gory 3 and Performance Level (PL) d according to EN ISO 13849-1.

6.6.4 X19 KUKA smartPAD

Description The KUKA smartPAD is connected to interface X19.

Necessary  Intercontec series 615

equipment

Fig. 6-10: Contact diagram, view from contact side

Connector pin
Pin Description
allocation X19
11 TD+
12 TD-
2 RD+
3 RD-
8 smartPAD plugged in (A) 0 V
9 smartPAD plugged in (B) 24 V
5 24 V PS2
6 GND

6.6.5 X21 RDC interface

Description The RDC of the robot is connected to interface X21.

Necessary  Harting HAN3A/Q12

equipment

Fig. 6-11: Contact diagram, view from contact side

Connector pin
Pin Description
allocation X21
1 +24 V with battery back-up
2 GND
5 +24 V without battery backup
6 GND
9 TD+
11 TD-
10 RD+

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Pin Description
12 RD-
- PE

6.6.6 X21 US2 RDC interface

Description For the X21 US2 RDC interface, the buffered US1 voltage is used to supply
power to the RDC of the robot. The US2 voltage is implemented as switchable
using safe technology. This deactivates actuators via a Beckhoff board, for ex-
ample, when the drives are deactivated.
This function exists in the following three variants and is set in the safety con-
figuration:
 Switched by an external PLC:
The contactor is switched directly by an external input (US2 signal in the
PROFIsafe/CIP Safety/FSoE telegram). This variant is available only if
PROFIsafe/CIP Safety/FSoE is in use.
 Switched by the KRC:
The contactor is switched if the “FF signal” and the non-safe
“US2_CONTACTOR_ON” signal from the robot controller are set. In this
way, the non-safe part of the robot controller can also switch the contactor.
 Deactivated:
The contactor is always off.
If, due to a fault in the system cabling, there is a cross connection between
US1 and US2, this will not be noticed during normal operation. The result is
that load voltage US2 is no longer switched off which can lead to a dangerous
state in the system.

In the cabling for the voltages US1 and US2 in the system, suitable
measures must be taken to prevent a cross-connection between the
voltages (e.g. separate cabling of US1 and US2 or a cable with rein-
forced insulation between the two voltages).

The function of the load voltage contactors must be checked in accor-

dance with (>>> 6.6.7 "Checking the US2 function, load voltage con-
tactor" Page 68).

If the US2 option is used, the signaling of the US2 states must be
checked (at US2) before the process periphery is started up.

Necessary  Harting HAN3A/Q12

equipment

Fig. 6-12: Contact diagram, view from contact side

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Connector pin
Pin Description
allocation X21
1 +24 V with battery back-up
2 GND
5 US2 +24 V switched
6 GND
9 TD+
11 TD-
10 RD+
12 RD-
- PE

Voltage US2 is switched via contactors Q5 and Q6. The fuse is located on the
CCU_SR.

6.6.7 Checking the US2 function, load voltage contactor

The US2 function must be checked in the following cases:

 Following initial start-up or recommissioning of the industrial robot
 After a change to the industrial robot
 After a change to the safety configuration
 After a software update, e.g. of the System Software
 After the load voltage contactors have been exchanged

Procedure  PROFIsafe or CIP Safety:

Set US2 input; contactor switches on.
Reset US2 input; contactor switches off.
 Automatic:
Press enabling switch; contactor switches on; manipulator can be moved.
Release enabling switch; contactor switches off.
 Deactivated:
In this configuration, it is not necessary to check the US2 contactor. The
outputs must not be used.

External PLC In this configuration, the US2 contactor can be checked by deactivating the in-
put “Peripheral contactor (US2)” in the PROFIsafe or CIP Safety telegram.

KRC In this configuration, the US2 contactor can be checked by opening the oper-
ator safety device (safeguard) in “Automatic” or “Automatic External” mode
and releasing the enabling switch in “T1” or “T2” mode.

6.7 Equipotential bonding

Description The following cables must be connected before start-up:

 A 4 mm2 cable as equipotential bonding between the manipulator and the

robot controller
 An additional equipotential bonding cable between the central PE rail of
the supply cabinet and the PE connection of the robot controller
A cross section of 4 mm2 is recommended.
 In the case of a KR C4 smallsize-2 with a drive box mounted on it, a PE
conductor with a cross-section of 16 mm2 must be connected between the
KR C4 smallsize-2 drive box and the equipotential bonding of the produc-

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tion shop. No additional 4 mm2 cable is required between the controller

and the equipotential bonding of the production shop.

Fig. 6-13: Equipotential bonding between the manipulator and the robot
controller

1 Equipotential bonding connection on the manipulator

2 Equipotential bonding between the manipulator and the robot con-
troller
3 Equipotential bonding connections on the robot controller
4 Equipotential bonding to the central PE rail of the supply cabinet

6.8 Performance level

The safety functions of the robot controller conform to Category 3 and Perfor-
mance Level d according to EN ISO 13849-1.

6.8.1 PFH values of the safety functions

The safety values are based on a service life of 20 years.

The PFH value classification of the controller is only valid if the E-STOP device
is tested at least once every 12 months.
When evaluating system safety functions, it must be remembered that the
PFH values for a combination of multiple controllers may have to be taken into
consideration more than once. This is the case for RoboTeam systems or
higher-level hazard areas. The PFH value determined for the safety function
at system level must not exceed the limit for PL d.
The PFH values relate to the specific safety functions of the different controller
variants.
Safety function groups:
 Standard safety functions
 Operating mode selection
 Operator safety
 EMERGENCY STOP device
 Enabling device
 External safe operational stop
 External safety stop 1
 External safety stop 2
 Velocity monitoring in T1

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 KR C4 smallsize-2

 Control of the peripheral contactor

 Safety functions of KUKA Safe Operation Technology (optional)
 Monitoring of axis spaces
 Monitoring of Cartesian spaces
 Monitoring of axis velocity
 Monitoring of Cartesian velocity
 Monitoring of axis acceleration
 Safe operational stop
 Tool monitoring
Overview of controller variant PFH values:

Robot controller variant PFH value

KR C4; KR C4 CK < 1 x 10-7
KR C4 midsize; KR C4 midsize CK < 1 x 10-7
KR C4 extended; KR C4 extended CK < 1 x 10-7
KR C4 NA; KR C4 CK NA < 1 x 10-7
KR C4 NA variant: TTE1 < 1 x 10-7
KR C4 NA extended; KR C4 CK NA extended < 1 x 10-7
KR C4 variant: TBM1 < 1 x 10-7
KR C4 variants: TDA1; TDA2; TDA3; TDA4 < 1 x 10-7
KR C4 smallsize-2 variants: TDA4 < 1 x 10-7
KR C4 variants: TFO1; TFO2 < 2 x 10-7
KR C4 variants: TRE1; TRE2 < 1.7 x 10-7
KR C4 variant: TRE3 < 1 x 10-7
KR C4 variants: TVO1; TVO2; TVO3 < 1 x 10-7
VKR C4 variants: TVW1; TVW2; TVW3; TVW4, TVW5, < 1 x 10-7
TVW6
VKR C4 smallsize-2 variants: TVW1; TVW3 < 1 x 10-7
VKR C4 Retrofit
 Without external EMERGENCY STOP and operator < 1 x 10-7
safety functions
 External EMERGENCY STOP and operator safety 5 x 10-7
functions
KR C4 Panel Mounted < 1 x 10-7
KR C4 SC1PA passenger < 6 x 10-9
KR C4 compact < 1 x 10-7
KR C4 compact slimline < 1 x 10-7
KR C4 smallsize < 1 x 10-7
KR C4 smallsize-2 < 1 x 10-7
KR C4 smallsize-2 with KR C4 smallsize drive box < 1 x 10-7

For controller variants that are not listed here, please contact KUKA
Deutschland GmbH.

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 7 Transportation

7
T
Transportation
s

7.1 Transportation using lifting tackle

t

Precondition The robot controller must be switched off.

t


 No cables may be connected to the robot controller.
 The door of the robot controller must be closed.
 The robot controller must be upright.

Necessary  Lifting tackle

equipment  4 M8 DIN 580 eyebolts

Procedure 1. Attach the lifting tackle with a lifting frame to all 4 transport eyebolts on the
control cabinet.

Fig. 7-1: Transportation using lifting tackle

1 Eyebolts
2 Correctly attached lifting frame
3 Correctly attached lifting tackle
4 Incorrectly attached lifting tackle

2. Attach the lifting tackle to the crane.

If the suspended robot controller is transported too quick-

ly, it may swing and cause injury or damage. Transport
the robot controller slowly.

3. Slowly lift and transport the robot controller.

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4. Slowly lower the robot controller at its destination.

5. Unhook lifting tackle on the robot controller.

7.2 Transportation by pallet truck

Precondition  The robot controller must be switched off.

 No cables may be connected to the robot controller.
 The door of the robot controller must be closed.
 The robot controller must be upright.

Procedure 1. Fasten the robot controller to a transport pallet.

2. Transport the robot controller carefully with a pallet truck.

7.3 Transportation with the set of rollers

Description The robot controller rollers may only be used to roll the cabinet into and out of
a row of cabinets – not to transport the cabinet over longer distances. The floor
must be level and free from obstacles, as there is a permanent risk of toppling.

If the robot controller is towed by a vehicle (fork lift truck,

electrical vehicle), this can result in damage to the rollers
and to the robot controller. The robot controller must not be hitched to a ve-
hicle and transported using its rollers.

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 8 Start-up and recommissioning

8 Start-up and recommissioning

t

8.1 Start-up

Working with electrostatic sensitive devices necessitates special pre-

cautionary measures. Measures against static discharge and electric
fields are to be found in DIN EN 61340-5-1.

This is an overview of the most important steps during start-up. The

precise sequence depends on the application, the manipulator type,
the technology packages used and other customer-specific circum-
stances.
For this reason, the overview does not claim to be comprehensive.

Precondition  No condensation has formed in the robot controller.

8.2 Installing the robot controller

Procedure 1. Only install the robot controller horizontally.

2. Install the robot controller. The minimum clearances to walls, other cabi-
nets, etc. must be observed.
3. Check the robot controller for any damage caused during transportation.
4. Check that fuses, contactors and boards are fitted securely.
5. Secure any modules that have come loose.
6. Check that all screwed and clamped connections are securely fastened.
7. The operator must cover the warning label Read manual with the label in
the relevant local language.

8.3 Connecting the connecting cables

Overview  A connecting cable set is supplied with the industrial robot. In the standard
version this consists of:
 Motor cables to the manipulator
 Data cables to the manipulator
 The following cables may be provided for additional applications:
 Motor cables for external axes
 Peripheral cables

Bending radius The following bending radii must be observed:

 Fixed installation: 3 ... 5 x cable diameter.
 Installation in cable carrier: 7 ... 10 x cable diameter (cable must be spec-
ified for this).

Procedure
The robot controller is preconfigured for the specific in-
dustrial robot. If cables are interchanged, the manipula-
tor and the external axes (optional) may receive incorrect data and can thus
cause personal injury or material damage. If a system consists of more than
one manipulator, always connect the connecting cables to the manipulators
and their corresponding robot controllers.

Route the connecting cables between the robot and the

control cabinet in such a way as to exclude the possibility
of damage to the cables.

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1. Route and connect the motor cables to the manipulator junction box sep-
arately from the data cables.
2. Route and connect the motor cables of the external axes.

Following a defect with subsequent exchange of the data

cable, the mastering may be incorrect. This may cause
personal injury or material damage. Following an exchange of the data cable,
carry out mastering or perform a mastering test of all axes.

3. Route the data cables to the manipulator junction box separately from the
motor cable. Plug in connector X21.
4. Connect the peripheral cables.

Fig. 8-1: Example: Installing the cables in the cable duct

1 Cable duct 4 Motor cables

2 Separating webs 5 Data cables
3 Welding cables

8.4 Connecting the equipotential bonding (PE)

Procedure 1. Connect an additional PE conductor between the central PE rail of the

supply cabinet and the PE bolt of the robot controller.
2. Connect a 4 mm2 cable as equipotential bonding between the manipulator
and the robot controller.
3. Check the conditions for protection by means of automatic switch-off of the
power supply as per Section 18.2 in accordance with EN 60204-1 (Test 1
+ 2).

Fig. 8-2: Equipotential bonding between the manipulator and the robot
controller

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 8 Start-up and recommissioning

1 Equipotential bonding connection on the manipulator

2 Equipotential bonding between the manipulator and the robot con-
troller
3 Equipotential bonding connections on the robot controller
4 Equipotential bonding to the central PE rail of the supply cabinet

8.5 Reversing the battery discharge protection measures

Description To prevent the batteries from discharging before the controller has been start-
ed up for the first time, the robot controller is supplied with connector X305 dis-
connected from the CCU_SR.

Procedure  Plug connector X305 into the CCU_SR.

Fig. 8-3: Battery discharge protection X305

1 Connector X305 on the CCU_SR

8.6 Power supply connection via X1 Harting connector

Description The robot controller is connected to the mains via a Harting connector X1.

If the robot controller is connected to a power system

without a grounded neutral, this may cause malfunc-
tions in the robot controller and material damage to the power supply units.
Electrical voltage can cause injuries. The robot controller may only be oper-
ated with grounded-neutral power supply systems.

Precondition  The robot controller is switched off.

 The power cable is de-energized.

Procedure  Connect the robot controller to the power supply via X1.

Connector pin
Pin Description
allocation X1
1 L1
2 L2

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Pin Description
3 L3
PE PE

8.7 Modifying the system configuration, exchanging devices

Description The system configuration of the industrial robot must be configured using
WorkVisual in the following cases:
 New installation of KUKA System Software

Observe compatibility.

 The hard drive has been exchanged.

 A device has been replaced by a device of a different type.
 More than one device has been replaced by a device of a different type.
 One or more devices have been removed.
 One or more devices have been added.

Exchanging If a device is exchanged, at least one KCB, KSB or KEB device is replaced by
devices a device of the same type. Any number of KCB, KSB and KEB devices can be
exchanged until all devices in the KCB, KSB and KEB have been replaced si-
multaneously by devices of the same type. Simultaneous exchange of two
identical components of the KCB is not possible. Only one of the identical com-
ponents may be exchanged at any one time.

8.8 Start-up mode

Description The industrial robot can be set to Start-up mode via the smartHMI user inter-
face. In this mode, the manipulator can be moved in T1 without the external
safeguards being put into operation.
When Start-up mode is possible depends on the safety interface that is used.
Discrete safety interface
Start-up mode is always possible. This also means that it is independent of the
state of the inputs at the discrete safety interface.
If an additional discrete safety interface is used for safety options: The states
of these inputs are also irrelevant.
Ethernet safety interface
The robot controller prevents or terminates Start-up mode if a connection to a
higher-level safety system exists or is established.

Description The industrial robot can be set to Start-up mode via the smartHMI user inter-
face. In this mode, the manipulator can be moved in T1 without the external
safeguards being put into operation.
The safety interface used affects “Start-up” mode:
Discrete safety interface
 System Software 8.2 or earlier:
Start-up mode is always possible if all input signals at the discrete safety
interface have the state “logic zero”. If this is not the case, the robot con-
troller prevents or terminates Start-up mode.
If an additional discrete safety interface for safety options is used, the in-
puts there must also have the state “logic zero”.

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 8 Start-up and recommissioning

 System Software 8.3 or higher:

Start-up mode is always possible. This also means that it is independent
of the state of the inputs at the discrete safety interface.
If an additional discrete safety interface is used for safety options: The
states of these inputs are also irrelevant.
Ethernet safety interface
The robot controller prevents or terminates Start-up mode if a connection to a
higher-level safety system exists or is established.

Hazards Possible hazards and risks involved in using Start-up mode:

 A person walks into the manipulator’s danger zone.
 In a hazardous situation, a disabled external EMERGENCY STOP device
is actuated and the manipulator is not shut down.
Additional measures for avoiding risks in Start-up mode:
 Cover disabled EMERGENCY STOP devices or attach a warning sign in-
dicating that the EMERGENCY STOP device is out of operation.
 If there is no safety fence, other measures must be taken to prevent per-
sons from entering the manipulator’s danger zone, e.g. use of warning
tape.

External safeguards are disabled in Start-up mode. Ob-

serve the safety instructions relating to Start-up mode.
(>>> 5.8.3.2 "Start-up mode" Page 47)

In Start-up mode, the system switches to the following simulated input image:
 The external EMERGENCY STOP is not active.
 The safety gate is open.
 No safety stop 1 has been requested.
 No safety stop 2 has been requested.
 No safe operational stop has been requested.
 Only for VKR C4: E2/E22 is closed.
If SafeOperation or SafeRangeMonitoring is used, Start-up mode also influ-
ences other signals.

Information about the effects of Start-up mode in conjunction with Sa-

feOperation or SafeRangeMonitoring can be found in the documen-
tation SafeOperation and SafeRangeMonitoring.

Mapping of standard signals:

Byte 0: 0100 1110
Byte 1: 0100 0000
SafeOperation or SafeRangeMonitoring signal mapping:
Byte 2: 1111 1111
Byte 3: 1111 1111
Byte 4: 1111 1111
Byte 5: 1111 1111
Byte 6: 1000 0000
Byte 7: 0000 0000

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8.9 Switching on the robot controller

Precondition  The door of the robot controller is closed.

 All electrical connections are correct and the power supply is within the
specified limits.
 It must be ensured that no persons or objects are present within the dan-
ger zone of the manipulator.
 All safety devices and protective measures are complete and fully func-
tional.
 The internal temperature of the cabinet must have adapted to the ambient
temperature.

We recommend that all motions of the manipulator should be trig-

gered from outside the safety fencing.

Procedure 1. Switch on the mains power to the robot controller.

2. Release the E-STOP device on the KUKA smartPAD.
3. Switch on the main switch. The control PC begins to boot the operating
system and the control software.

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9 Operation

9.1 KUKA smartPAD teach pendant

t

9.1.1 Front view

Function The smartPAD is the teach pendant for the industrial robot. The smartPAD has
all the operator control and display functions required for operating and pro-
gramming the industrial robot.
The smartPAD has a touch screen: the smartHMI can be operated with a fin-
ger or stylus. An external mouse or external keyboard is not necessary.

Overview

Fig. 9-1: KUKA smartPAD, front view

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Item Description
1 Button for disconnecting the smartPAD

2 Mode selector switch. The switch may be one of the following vari-
ants:
 With key
 Without key
The mode selector switch is used to call the connection manager.
The operating mode can be changed by using the connection man-
ager.

3 EMERGENCY STOP device Stops the robot in hazardous situa-

tions. The EMERGENCY STOP button locks itself in place when it
is pressed.
4 Space Mouse: For moving the robot manually
5 Jog keys: For moving the robot manually
6 Key for setting the program override
7 Key for setting the jog override
8 Main menu key: Shows the menu items on the smartHMI

9 Status keys. The status keys are used primarily for setting param-
eters in technology packages. Their exact function depends on the
technology packages installed.
10 Start key: The Start key is used to start a program.
11 Start backwards key: The Start backwards key is used to start a
program backwards. The program is executed step by step.
12 STOP key: The STOP key is used to stop a program that is run-
ning.
13 Keyboard key
Displays the keyboard. It is generally not necessary to press this
key to display the keyboard, as the smartHMI detects when key-
board input is required and displays the keyboard automatically.

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9.1.2 Rear view

Overview

Fig. 9-2: KUKA smartPAD, rear view

1 Enabling switch 4 USB connection

2 Start key (green) 5 Enabling switch
3 Enabling switch 6 Identification plate

Description Element Description

Rating plate Rating plate
Start key The Start key is used to start a program.
The enabling switch has 3 positions:
 Not pressed
 Center position
 Fully pressed (panic position)
Enabling
switch The enabling switch must be held in the center position
in operating modes T1 and T2 in order to be able to jog
the manipulator.
In the operating modes Automatic and Automatic Exter-
nal, the enabling switch has no function.
The USB connection is used, for example, for archiving
USB connec- and restoring data.
tion
Only for FAT32-formatted USB sticks.

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 10 Maintenance

10 Maintenance
Description
t Maintenance work must be performed at the specified maintenance intervals
after commissioning at the customer’s plant.

10.1 Maintenance symbols

Maintenance
The overview may contain maintenance symbols that are not relevant
symbols for the maintenance work on this product. The maintenance illustra-
tions provide an overview of the relevant maintenance work.

Oil change

Lubricate with grease gun

Lubricate with brush

Lubricate with spray grease

Tighten screw/nut

Check component, visual inspection

Clean component

Exchange battery

Exchanging the toothed belt

Check toothed belt tension

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.

Cables routed from power supply connection X1 to the

main switch are energized even when the main switch is
switched off! This mains voltage can cause injuries on contact.

 The power cable is de-energized.

 Observe the ESD guidelines.

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Fig. 10-1: Maintenance points

Interval Item Activity

1 year 1 Check the utilized relay outputs of the CCU_SR for
correct functioning (>>> 10.2 "Checking CCU_SR
relay outputs" Page 84)
- Cyclical function test of operator safety and external
EMERGENCY STOP devices
1 year at 2 Depending on installation conditions and degree of
the latest fouling, clean the protective grille of the external fan
with a brush.
2 years at 6 Depending on installation conditions and degree of
the latest fouling, clean the cooling fins of the drives with a
brush.
2 Depending on installation conditions and degree of
fouling, clean the external fan with a brush.
3 Depending on installation conditions and degree of
fouling, clean the heat sinks of the low-voltage power
supply unit with a brush.
- Depending on installation conditions and degree of
fouling, clean the robot controller.
5 years 5 Exchange the motherboard battery
5 years 4 Exchange the control PC fan.
(with 3-shift 2 Exchange the external fan.
operation)
As indicat- 7 Exchange the batteries
ed by the
battery
monitoring

10.2 Checking CCU_SR relay outputs

Activity Check the function of the output Local EMERGENCY STOP.

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Procedure  Press the local EMERGENCY STOP device.

Activity Check the function of the output Operator safety acknowledged.

Procedure 1. Set operating mode to Automatic or Automatic External.

2. Open operator safety (safeguard).

Activity Check the function of the output Switch on periphery.

Procedure 1. Set operating mode to Automatic or Automatic External.

2. Open operator safety (safeguard).
3. Release enabling switch in “T1” or “T2” mode.
If no error message is displayed, the relay outputs are OK.

10.3 Cleaning the robot controller

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 Power supply lead disconnected.
 Observe the ESD guidelines.

Work regulations  The manufacturer’s instructions must be observed when using cleaning
agents for cleaning work.
 It must be ensured that no cleaning agents enter electrical components.
 Do not use compressed air during cleaning work.
 Do not spray with water.

Procedure 1. Loosen and vacuum up any dust deposits.

2. Clean the housing of the robot controller with a cloth soaked with a mild
cleaning agent.
3. Clean cables, plastic parts and hoses with a solvent-free cleaning agent.
4. Replace damaged, illegible or missing identifications, labels and plates.

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 11 Repair

11 Repair

11.1 Repair and procurement of spare parts

Repair Repairs to the robot controller may only be carried out by KUKA customer sup-
port personnel or by customers who have taken part in a relevant course of
training held by KUKA Deutschland GmbH.
Repairs within modules may only be carried out by specially trained KUKA
Deutschland GmbH personnel.

Procurement of The article numbers of the spare parts are listed in the spare parts catalog.
spare parts KUKA Deutschland GmbH supplies the following types of spare parts for re-
pairs to the robot controller:
 New parts
Once the new part has been installed, the part that has been removed can
be disposed of.
 Exchange parts
Once the exchange part has been installed, the part that has been re-
moved is returned to KUKA Deutschland GmbH.

A “Robot Repair Card” is supplied with the exchange parts. The Re-
pair Card must be completed and returned to KUKA Deutschland
GmbH.

11.2 Exchanging the external fan

Description The following instructions describe the exchange of the external fan on a robot
controller.

Equipment The following equipment is required:

Designation Article number

Crosstip screwdrivers -
PZ 1, 2
ESD wristband -

Material The following material is required:

Designation Article number Quantity

Fan DC 190mm 0000-171-602 1

Overview The instructions are subdivided into the following work steps:

Work step Activity

1 Exchanging the external fan

2 Concluding work
(>>> 11.2.3 "Concluding work" Page 90)

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 The power cable must be de-energized.

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Cables routed from power supply connection X1 to the

main switch are energized even when the main switch is
switched off! This mains voltage can cause injuries on contact.

 Observe the ESD guidelines.

Work safety
When work is performed on this system, live parts and
unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operable system, the main switch
on the control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on again.
Warn all persons concerned before putting the system back into operation.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again by unauthorized personnel. The incoming
power cable must be deenergized. The robot controller and mains supply
lead must then be checked to ensure that it is deenergized.
Failure to observe this precaution may result in death or injuries.

The ESD guidelines must be observed. Failure to do so

can result in destruction of or partial damage to the com-
ponent.

11.2.1 Removing the external fan

Procedure 1. Unplug fan connector X14 on the CCU_SR.

2. Unscrew the 4 screws from the rear panel and remove the rear panel.

Fig. 11-1: Removing the rear panel

1 Fastening of rear panel

2 Fan connector X14 on the CCU_SR

3. Remove the screws of the cable inlet.

4. Swivel back the cable inlet and pull out the connecting cable.

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Fig. 11-2: External fan, cable inlet

1 Fastening of cable inlet

2 Cover of the cable inlet

5. Remove the fan holder together with the fan.

11.2.2 Installing the external fan

Procedure 1. Install the new fan together with its holder and fasten.

Fig. 11-3: Exchanging the external fan

1 Fastening of the fan holder

2. Route the connecting cable in the cabinet.

3. Mount the cable inlet.

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Fig. 11-4: External fan, cable inlet

1 Fastening of cable inlet

2 Cover of the cable inlet

4. Insert and fasten the rear panel.

5. Plug in fan connector X14 on the CCU_SR.

Fig. 11-5: Removing the rear panel

1 Fastening of rear panel

2 Fan connector X14 on the CCU_SR

11.2.3 Concluding work

After the external fan has been exchanged, the following tasks must be carried
out:

General tasks  Boot the controller and look out for irregularities.

11.3 Exchanging the drive unit

Description The following instructions describe the exchange of the drive unit on a robot
controller.

Equipment The following equipment is required:

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 11 Repair

Designation Article number

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
ESD wristband

Material The following material is required:

Designation Article number Quantity

drive unit complet smallsize-2 0000-259-952 1

Overview The instructions are subdivided into the following work steps:

Work step Activity

1 Exchanging the drive unit

2 Concluding work
(>>> 11.3.3 "Concluding work" Page 93)

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 Power supply lead disconnected.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

The following components may remain energized

(50...330 V) up to 5 minutes after the robot controller has
been switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for motor connector X20 and connected motor cables
This voltage can cause life-threatening injuries.

Work safety
When work is performed on this system, live parts and
unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operable system, the main switch
on the control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on again.
Warn all persons concerned before putting the system back into operation.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again by unauthorized personnel. The incoming
power cable must be deenergized. The robot controller and mains supply
lead must then be checked to ensure that it is deenergized.
Failure to observe this precaution may result in death or injuries.

The ESD guidelines must be observed. Failure to do so

can result in destruction of or partial damage to the com-
ponent.

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11.3.1 Removing the drive unit

Procedure 1. Unplug all connections from the drive unit.

Fig. 11-6: Connections on the drive unit

2. Unscrew the 2 knurled screws on the front of the drive unit with a hexagon
wrench.

Fig. 11-7: Drive unit removed

1 Handgrips
2 Knurled screws

3. Pull the drive unit forwards by the handgrips to remove it.

11.3.2 Installing the drive unit

Procedure 1. Place the new drive unit on the support rails and fasten with the knurled
screws.

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Fig. 11-8: Drive unit removed

1 Handgrips
2 Knurled screws

2. Plug in the connections of the drive unit in accordance with the connector
and cable labeling.

Fig. 11-9: Connections on the drive unit

11.3.3 Concluding work

After the drive unit has been exchanged, the following tasks must be carried
out:

General tasks  Check that all of the connectors on the drive unit are fitted securely before
starting up the controller.
 Boot the controller and look out for irregularities.

11.4 Exchanging control PC components

11.4.1 Exchanging the control PC

Description The following instructions describe the exchange of the control PC on a robot
controller.

Equipment The following equipment is required:

Designation Article number

ESD wristband -

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 KR C4 smallsize-2

Material The following material is required:

Designation Article number Quantity

PC for KR C4 0000-255-229 1

Overview The instructions are subdivided into the following work steps:

Work step Activity

1 Exchanging the control PC

2 Concluding work
(>>> 11.4.1.3 "Concluding work" Page 95)

Precondition  Observe the ESD guidelines.

 From KSS 8.3.20 and from motherboard D3236-K onwards:
 Board Package USB stick in the USB port.

Work safety
When work is performed on this system, live parts and
unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operable system, the main switch
on the control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on again.
Warn all persons concerned before putting the system back into operation.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again by unauthorized personnel. The incoming
power cable must be deenergized. The robot controller and mains supply
lead must then be checked to ensure that it is deenergized.
Failure to observe this precaution may result in death or injuries.

The ESD guidelines must be observed. Failure to do so

can result in destruction of or partial damage to the com-
ponent.

11.4.1.1 Removing the control PC

Procedure

Fig. 11-10: Fastening elements of the control PC

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1 Knurled nut
2 Tilt the PC
3 Lift the PC

1. Shut down the robot controller with the settings Cold start and Reload
files.
2. Turn off the robot controller using the main switch and take measures to
prevent it from being turned on again unintentionally.
3. Disconnect the power cable from the supply.

Cables routed from power supply connection X1 to the

main switch are energized even when the main switch is
switched off! This mains voltage can cause injuries on contact.

4. Unplug the power supply and all connections to the control PC.
5. Slacken the knurled nuts.
6. Remove the control PC and lift it out towards the top.

11.4.1.2 Installing the control PC

Procedure

Fig. 11-11: Fastening elements of the control PC

1 Knurled nut
2 Tilt the PC
3 Lift the PC

1. Insert the new control PC and fasten.

2. Plug in the connections.
3. For network cable connection, see (>>> 3.3 "Control PC" Page 12).
4. Switch on the robot controller.
5. From KSS 8.3 and from motherboard D3236-K onwards:
 Once the controller has been successfully started, disconnect the
Board Package USB stick and carefully store it.
Starting and installing the drivers may take some time.

11.4.1.3 Concluding work

After the control PC has been exchanged, the following tasks must be carried
out:

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 KR C4 smallsize-2

General tasks  Boot the controller and look out for irregularities.

11.4.2 PC fan

Description The following instructions describe the exchange of the PC fan on a robot con-
troller.

Equipment The following equipment is required:

Designation Article number

ESD wristband -

Material The following material is required:

Designation Article number Quantity

KPC MC - fan assembly lc 0000-253-564 1

Overview The instructions are subdivided into the following work steps:

Work step Activity

1 Exchanging the PC fan

2 Concluding work
(>>> 11.4.2.3 "Concluding work" Page 98)

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 The power cable must be de-energized.

Cables routed from power supply connection X1 to the

main switch are energized even when the main switch is
switched off! This mains voltage can cause injuries on contact.

 Observe the ESD guidelines.

Work safety
When work is performed on this system, live parts and
unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operable system, the main switch
on the control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on again.
Warn all persons concerned before putting the system back into operation.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again by unauthorized personnel. The incoming
power cable must be deenergized. The robot controller and mains supply
lead must then be checked to ensure that it is deenergized.
Failure to observe this precaution may result in death or injuries.

The ESD guidelines must be observed. Failure to do so

can result in destruction of or partial damage to the com-
ponent.

11.4.2.1 Removing the PC fan

Procedure 1. Remove the control PC.

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2. Remove air duct, if present.

3. Remove the control PC cover.
4. Release and unplug the fan connector. Depending on the variant, the fan
connector is located either on the housing or directly on the motherboard.

Fig. 11-12: Disconnecting control PC fan from housing or motherboard

1 Fan connector 4 Fan grille

2 Control PC housing 5 CPU fan
3 Fan

5. Remove outer fan grille.

6. Pull the fan inwards off the mounting plugs.
7. Remove the expanding rivets and take off the inner fan grille.

Fig. 11-13: PC fan configuration

1 Mounting plugs 4 Fan grille (optional, depending

on variant)
2 Outer fan grille 5 Fan identification plate
3 Fastening of fan grille (ex-
panding rivets)

11.4.2.2 Installing the PC fan

Procedure 1. Fasten the inner fan grille to the new fan with the expanding rivets.

The fan grille must be fastened to the side with the identification plate.
See (>>> Fig. 11-13 )

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Fig. 11-14: Installing the control PC fan

1 Mounting plug on fan 3 Mounting plug on PC housing

2 Fan grille

2. Install the mounting plugs in the fan.

3. Insert the fan into the PC housing and pull the mounting plugs through the
PC housing.
4. Attach the outer fan grille.
5. Mount the air duct.

11.4.2.3 Concluding work

After the PC fan has been exchanged, the following tasks must be carried out:

General tasks  Boot the controller and look out for irregularities.

11.4.3 Exchanging the motherboard battery

The battery on the motherboard of the control PC may only be exchanged by

authorized maintenance personnel in consultation with the KUKA customer
support service.

11.4.4 Exchanging the motherboard

A defective motherboard is not exchanged separately, but together with the

control PC.

11.4.5 Exchanging the SSD hard drive

Description The following instructions describe the exchange of the SSD hard drive on a
KR C4 controller.

Equipment The following equipment is required:

Designation Article number

ESD wristband -

Material The following material is required:

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Designation Article number Quantity

KPC MC - SSD assy 0000-195-245 1

Overview The instructions are subdivided into the following work steps:

Work step Activity

1 Exchanging the SSD hard drive

2 Concluding work
(>>> 11.4.5.3 "Concluding work" Page 101)

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 The power cable must be de-energized.

Cables routed from power supply connection X1 to the

main switch are energized even when the main switch is
switched off! This mains voltage can cause injuries on contact.

 Observe the ESD guidelines.

Work safety
When work is performed on this system, live parts and
unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operable system, the main switch
on the control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on again.
Warn all persons concerned before putting the system back into operation.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again by unauthorized personnel. The incoming
power cable must be deenergized. The robot controller and mains supply
lead must then be checked to ensure that it is deenergized.
Failure to observe this precaution may result in death or injuries.

The ESD guidelines must be observed. Failure to do so

can result in destruction of or partial damage to the com-
ponent.

11.4.5.1 Removing the SSD hard drive

Procedure

Fig. 11-15: Exchanging the hard drive

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 KR C4 smallsize-2

1 SATA connector
2 Power supply connector
3 Knurled screws on the underside

1. Slacken the knurled screws of the SSD hard drive.

2. Release and unplug the SATA connector.
3. Unplug power supply connector.

11.4.5.2 Installing the SSD hard drive

Procedure 1. Slacken the knurled screws of the SSD.

2. Release and unplug the SATA connector.
3. Unplug power supply connector.
4. Remove the hard drive and replace it with a new one.
5. Plug in the SATA and power supply connectors.
6. Fasten the hard drive with the knurled screws.
7. Install the operating system and the KUKA System Software (KSS).
8. The system configuration of the industrial robot must be configured using
WorkVisual.

Once the hard drive has been exchanged, the following options are
available in addition to configuration using WorkVisual:
Load the archive of the previous installation.
 Restore the complete image using the KUKA Recovery Tool.

Fig. 11-16: Exchanging the hard drive

1 SATA connector
2 Power supply connector
3 Knurled screws on the underside

Procedure 1. Insert the new SSD hard drive into the controller.
2. Plug in the SATA and power supply connectors.
3. Fasten the hard drive with the knurled screws.
4. Install the operating system and the KUKA System Software (KSS).
5. The system configuration of the industrial robot must be configured using
WorkVisual.

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Once the hard drive has been exchanged, the following options are
available in addition to configuration using WorkVisual:
Load the archive of the previous installation.
 Restore the complete image using the KUKA Recovery Tool.

11.4.5.3 Concluding work

After the SSD hard drive has been exchanged, the following tasks must be
carried out:

General tasks  Boot the controller and look out for irregularities.

11.5 Exchanging the batteries

Description The following instructions describe the exchange of the batteries on a robot
controller.

Equipment The following equipment is required:

Designation Article number

ESD wristband -

Material The following material is required:

Designation Article number Quantity

Battery CP1250H 12V/5.0/5.2Ah 0000-115-723 2

Overview The instructions are subdivided into the following work steps:

Work step Activity

1 Exchanging the batteries
(>>> 11.5 "Exchanging the batteries" Page 101)
2 Concluding work
(>>> 11.5.3 "Concluding work" Page 103)

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 The power cable must be de-energized.

Cables routed from power supply connection X1 to the

main switch are energized even when the main switch is
switched off! This mains voltage can cause injuries on contact.

 Observe the ESD guidelines.

Work safety
When work is performed on this system, live parts and
unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operable system, the main switch
on the control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on again.
Warn all persons concerned before putting the system back into operation.

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 KR C4 smallsize-2

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again by unauthorized personnel. The incoming
power cable must be deenergized. The robot controller and mains supply
lead must then be checked to ensure that it is deenergized.
Failure to observe this precaution may result in death or injuries.

The ESD guidelines must be observed. Failure to do so

can result in destruction of or partial damage to the com-
ponent.

Procedure 1. Unplug the battery connection cables.

A short-circuit or short to ground at the battery poles

causes a very high short-circuit current. This short-circuit
current can cause severe injury and substantial damage to property. It must
be ensured that no short-circuit or short to ground is caused at the battery
poles.

A short-circuit or short to ground at the battery poles can

trip the higher-level fuse. The batteries have no fuse of
their own. It must be ensured that no short-circuit or short to ground is caused
at the battery poles.

2. Remove both battery blocks from the battery holder on the side panel of
the robot controller.

The battery blocks must both be exchanged together.

3. Insert the new battery blocks and plug in the battery connection cables.

Fig. 11-17: Battery polarity

Observe the illustrated battery polarity. Installing the bat-

teries in the wrong position or with reversed polarity can
generate a high short-circuit current and trip the higher-level fuse.

11.5.1 Removing the batteries

Procedure 1. Unplug the battery connection cables.

A short-circuit or short to ground at the battery poles

causes a very high short-circuit current. This short-circuit
current can cause severe injury and substantial damage to property. It must
be ensured that no short-circuit or short to ground is caused at the battery
poles.

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A short-circuit or short to ground at the battery poles can

trip the higher-level fuse. The batteries have no fuse of
their own. It must be ensured that no short-circuit or short to ground is caused
at the battery poles.

2. Remove both battery blocks from the battery holder on the side panel of
the robot controller.

11.5.2 Installing the batteries

Procedure
The battery blocks must both be exchanged together.

1. Insert the new battery blocks and plug in the battery connection cables.

Fig. 11-18: Battery polarity

Observe the illustrated battery polarity. Installing the bat-

teries in the wrong position or with reversed polarity can
generate a high short-circuit current and trip the higher-level fuse.

11.5.3 Concluding work

After the batteries have been exchanged, the following tasks must be carried
out:

General tasks  Check that all of the connectors on the batteries are fitted securely before
starting up the controller.
 Boot the controller and look out for irregularities.

11.6 Exchanging the low-voltage power supply unit

Description The following instructions describe the exchange of the low-voltage power
supply unit on a robot controller.

Equipment The following equipment is required:

Designation Article number

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
ESD wristband

Material The following material is required:

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Designation Article number Quantity

27V IP54 supply 0000-169-213 1

Overview The instructions are subdivided into the following work steps:

Work step Activity

1 Exchanging the low-voltage power supply unit

2 Concluding work
(>>> 11.6.3 "Concluding work" Page 106)

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 Power supply lead disconnected.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

The following components may remain energized

(50...330 V) up to 5 minutes after the robot controller has
been switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for motor connector X20 and connected motor cables
This voltage can cause life-threatening injuries.

Work safety
When work is performed on this system, live parts and
unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operable system, the main switch
on the control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on again.
Warn all persons concerned before putting the system back into operation.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again by unauthorized personnel. The incoming
power cable must be deenergized. The robot controller and mains supply
lead must then be checked to ensure that it is deenergized.
Failure to observe this precaution may result in death or injuries.

The ESD guidelines must be observed. Failure to do so

can result in destruction of or partial damage to the com-
ponent.

11.6.1 Removing the low-voltage power supply unit

Procedure 1. Unscrew the 4 screws from the rear panel of the robot controller and re-
move the rear panel.

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Fig. 11-19: Removing the rear panel and low-voltage power supply unit

1 Fastening of rear panel

2 Fastening of low-voltage power supply unit

2. Unplug the connections of the low-voltage power supply unit inside the
cabinet:
 Power supply connector X2
 CCU_SR power infeed connector X1
 PE connector XPE
3. Unscrew 3 fastening screws of the low-voltage power supply unit.
4. Tilt the low-voltage power supply unit forward and lift it out vertically.

11.6.2 Installing the low-voltage power supply unit

Procedure 1. Insert the new low-voltage power supply unit and fasten with 3 screws.
2. Plug in the connections of the low-voltage power supply unit inside the
cabinet:
 Power supply connector X2
 CCU_SR power infeed connector X1
 PE connector XPE
3. Mount the rear panel on the rear of the controller and fasten with 4 screws.

Fig. 11-20: Removing the rear panel and low-voltage power supply unit

1 Fastening of rear panel

2 Fastening of low-voltage power supply unit

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11.6.3 Concluding work

After the low-voltage power supply unit has been exchanged, the following
tasks must be carried out:

General tasks  Check that all of the connectors on the low-voltage power supply unit are
fitted securely before starting up the controller.
 Boot the controller and look out for irregularities.

11.7 Exchanging the mains filter

Description The following instructions describe the exchange of the mains filter on a robot
controller.

Equipment The following equipment is required:

Designation Article number

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
ESD wristband -

Material The following material is required:

Designation Article number Quantity

line filter B84143 0000-266-210 1

Overview The instructions are subdivided into the following work steps:

Work step Activity

1 Exchanging the mains filter

2 Concluding work
(>>> 11.7.3 "Concluding work" Page 108)

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 Power supply lead disconnected.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

The following components may remain energized

(50...330 V) up to 5 minutes after the robot controller has
been switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for motor connector X20 and connected motor cables
This voltage can cause life-threatening injuries.

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Work safety
When work is performed on this system, live parts and
unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operable system, the main switch
on the control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on again.
Warn all persons concerned before putting the system back into operation.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again by unauthorized personnel. The incoming
power cable must be deenergized. The robot controller and mains supply
lead must then be checked to ensure that it is deenergized.
Failure to observe this precaution may result in death or injuries.

The ESD guidelines must be observed. Failure to do so

can result in destruction of or partial damage to the com-
ponent.

11.7.1 Removing the mains filter

Procedure 1. Unplug mains filter connecting cables.

Fig. 11-21

1 Connecting cables to the components (Load)

2 Mains filter
3 Equipotential bonding cable
4 Connecting cables from the power lead (Line)

2. Remove the equipotential bonding cable from the mains filter.

3. Unscrew both fastening screws and remove the mains filter.

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11.7.2 Installing the mains filter

Procedure

Fig. 11-22

1 Connecting cables to the components (Load)

2 Mains filter
3 Equipotential bonding cable
4 Connecting cables from the power lead (Line)

1. Insert the new mains filter and fasten.

2. Push on the connecting cables, paying attention to the correct polarity.
3. Connect the equipotential bonding cable.
4. Carry out a function test.

11.7.3 Concluding work

After the mains filter has been exchanged, the following tasks must be carried
out:

General tasks  Check that all of the connectors on the mains filter are fitted securely be-
fore starting up the controller.
 Boot the controller and look out for irregularities.

11.8 Exchanging the ballast resistor

Description The following instructions describe the exchange of the ballast resistor on a
robot controller.

Equipment The following equipment is required:

Designation Article number

Multimeter -
ESD wristband -

Material The following material is required:

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Designation Article number Quantity

ballast resistor 22Ohm 450mm 0000-259-498 1

Overview The instructions are subdivided into the following work steps:

Work step Activity

1 Exchanging the ballast resistor
(>>> 11.8 "Exchanging the ballast resistor" Page 108)
2 Concluding work
(>>> 11.8.3 "Concluding work" Page 111)

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 Power supply lead disconnected.
 Observe the ESD guidelines.
 Wait 5 minutes until the intermediate circuit has discharged.

The following components may remain energized

(50...330 V) up to 5 minutes after the robot controller has
been switched off:
 KPP_SR
 KSP_SR
 Intermediate circuit connecting cables
 Connections for motor connector X20 and connected motor cables
This voltage can cause life-threatening injuries.

Work safety
When work is performed on this system, live parts and
unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operable system, the main switch
on the control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on again.
Warn all persons concerned before putting the system back into operation.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again by unauthorized personnel. The incoming
power cable must be deenergized. The robot controller and mains supply
lead must then be checked to ensure that it is deenergized.
Failure to observe this precaution may result in death or injuries.

If removal is performed immediately after the robot con-

troller has been shut down, the heat sink surface temper-
atures are likely to be high and could result in burn injuries. Protective gloves
must be worn.

The ESD guidelines must be observed. Failure to do so

can result in destruction of or partial damage to the com-
ponent.

Procedure 1. Measure the resistance at KPP_SR with a multimeter at connector X3:

Measurement point Resistance

X3.1 to X3.2 20.4 - 23.8 Ω

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2. Check the cable:

 Cross-connection of individual wires
 Short-circuit of individual wires with the ground conductor
 Correct wiring in accordance with circuit diagram
If the resistance values are not observed and the cables are OK, exchange
the ballast resistor.
3. Remove the rear panel of the robot controller.
4. Unplug the connecting cables from the ballast resistor.
5. Loosen the fastening screws.

Fig. 11-23: Removing the ballast resistor

1 Fastening screw
2 Connections

6. Remove the ballast resistor.

7. Insert the new ballast resistor and fasten.
8. Push on the connecting cables, paying attention to the correct polarity.
9. Install the rear panel.

11.8.1 Removing the ballast resistor

Procedure 1. Measure the resistance at KPP_SR with a multimeter at connector X3:

Measurement point Resistance

X3.1 to X3.2 20.4 - 23.8 Ω

2. Check the cable:

 Cross-connection of individual wires
 Short-circuit of individual wires with the ground conductor
 Correct wiring in accordance with circuit diagram
3. If the resistance values are not observed and the cables are not OK, ex-
change the ballast resistor.
4. Remove the rear panel of the robot controller.
5. Unplug the connecting cables from the ballast resistor.
6. Loosen the fastening screws.

Fig. 11-24: Removing the ballast resistor

1 Fastening screw
2 Connections

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7. Remove the ballast resistor.

11.8.2 Installing the ballast resistor

Procedure 1. Insert the new ballast resistor and fasten.

Fig. 11-25: Removing the ballast resistor

1 Fastening screw
2 Connections

2. Push on the connecting cables, paying attention to the correct polarity.

3. Install the rear panel.

11.8.3 Concluding work

After the ballast resistor has been exchanged, the following tasks must be car-
ried out:

General tasks  Check that all of the connectors on the ballast resistor are fitted securely
before starting up the controller.
 Boot the controller and look out for irregularities.

11.9 Exchanging CCUsr

Description The following instructions describe the exchange of the CCUsr on a robot con-
troller.

Equipment The following equipment is required:

Designation Article number

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Crosstip screwdrivers -
PZ 1; 2
ESD wristband -

Material The following material is required:

Designation Article number Quantity

KRC4 smallsize CCUsr complete 0000-235-634 1

Overview The instructions are subdivided into the following work steps:

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 KR C4 smallsize-2

Work step Activity

1 Exchanging the CCUsr

2 Concluding work

Precondition  The robot controller must be switched off and secured to prevent unau-
thorized persons from switching it on again.
 Power supply lead disconnected.
 Observe the ESD guidelines.

Work safety
When work is performed on this system, live parts and
unintentional robot motions can cause injuries and dam-
age to property. If work is carried out on an operable system, the main switch
on the control cabinet must be turned to the OFF position and secured with
a padlock to prevent unauthorized persons from switching it on again.
Warn all persons concerned before putting the system back into operation.

Before work is commenced on live parts of the robot sys-

tem, the main switch must be turned off and secured
against being switched on again by unauthorized personnel. The incoming
power cable must be deenergized. The robot controller and mains supply
lead must then be checked to ensure that it is deenergized.
Failure to observe this precaution may result in death or injuries.

The ESD guidelines must be observed. Failure to do so

can result in destruction of or partial damage to the com-
ponent.

11.9.1 Removing the CCUsr

Connections

Fig. 11-26: Connections on the CCU_SR

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Con-
Item Description
nector
1 X46 KSB RoboTeam (yellow)
2 X48 KSB EtherCAT interface (green), optional
3 X45 KSB RoboTeam (red)
4 X29 EDS connection, memory card
5 X23 Fast Measurement inputs 1 to 5
6 X4 KPC supply and power supply fan
7 X307 UL lamp (optional)
8 X12 USB
9 X500 Not used
10 X501 Not used
11 X21 Power supply to RDC/EMD
12 X402 Safe inputs 1 to 3
13 X403 Safe inputs 4 to 7
14 X404 Safe inputs 8 to 9
15 X401 Mastering reference switch
16 X407 Safe input 11, teach pendant plugged in
17 X406 Safe outputs 12 to 15
18 X34 KCB RDC interface (white)
19 X31 KCB KPC interface (blue)
20 X32 KCB KPP interface (orange)
21 X33 I/O board (optional)
22 X41 KSB KPC interface (yellow)
23 X47 KSB spare (red)
24 X44 KSB KEI (white)
25 X43 KSB - KSI (blue)
26 X42 KSB - KOI (orange)
27 X3 Power supply to KPP_SR logic/brakes
28 X5 Power supply to options
29 X22 Power supply to options
30 X305 Battery infeed
31 X6 I/O board power supply without battery backup
(optional)
32 X301 24 V supply, spare
33 X1 Supply
34 X15 Power supply to power supply fan
35 X14 Power supply to external fan
36 X308 External power supply
37 X1700 Board connection to the PMB_SR
38 X405 Safe contactor output 10, single-channel input 10
39 X306 smartPAD power supply
40 X302 I/O board power supply with battery backup
(optional)
41 X25 Alarm contact, Power OK, power supply unit

1. Unlock the data cable connectors. Unplug all connections to the CCU_SR.

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 KR C4 smallsize-2

Unplugging the data cable connectors without first un-

locking them damages the connectors. Unlock the con-
nectors before unplugging them.

Fig. 11-27: Connector locking mechanism of data cable

1 Data connectors unlocked

2 Data connectors locked

2. Remove the screw from the fastening plate and remove the plate together
with the CCU_SR.

Fig. 11-28: CCU_SR fastening

1 Tabs
2 Screw of fastening plate with CCU_SR

11.9.2 Installing the CCUsr

Procedure 1. Check the new CCU_SR for mechanical damage. Insert the fastening
plate with the CCU_SR and screw it down.

Fig. 11-29: CCU_SR fastening

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 11 Repair

1 Tabs
2 Screw of fastening plate with CCU_SR

2. Plug in all the connections in accordance with the connector and cable la-
beling. Lock the data cable connectors.

Fig. 11-30: Connector locking mechanism of data cable

1 Data connectors unlocked

2 Data connectors locked

11.9.3 Concluding work

After the CCUsr has been exchanged, the following tasks must be carried out:

General tasks  Check that all of the connectors on the CCUsr are fitted securely before
starting up the controller.
 Boot the controller and look out for irregularities.

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 12 Troubleshooting

12
2
Troubleshooting
T

12.1 LED display on Cabinet Control Unit, Small Robot

s

Overview
t

Fig. 12-1: CCU_SR LED display

Item Designation Color Description Remedy

1 PHY4 Green On = OK -
Flashing = OK -
Off = fault Exchange CCU_SR module
2 SW_P0 Green On = OK -
Flashing = OK -
Off = fault Exchange CCU_SR module
3 RUN SION Green On = operational (normal -
state)
EtherCat
Safety nodes Off = Init (after switching on) -
Flashing at 2.5 Hz = Pre-Op -
(intermediate state on
startup)
Single signal = Safe Op -
Flashing at 10 Hz = boot (for -
firmware update)
4 L/A Green  On = physical connec- -
tion. Network cable
KSB
plugged in
5 L/A Green
 Off = no physical con-
100 Mbit
KSB KPC-MC nection. Network cable
Orange not plugged in
1 Gbit  Flashing = data traffic on
the line

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 KR C4 smallsize-2

Item Designation Color Description Remedy

6 PWR/3.3V Green Off = no supply voltage  Check fuse F17-3
present  Jumper plug X308 pres-
Power for the
CIB_SR ent
 Check fuse F308
 With external supply via
X308: Check external
supply voltage (rated
voltage 24 V)
On = supply voltage present -
7 PWR/2.5V Green Off = no supply voltage  Check fuse F17-3
present  Jumper plug X308 pres-
Power for the
CIB_SR ent
 Check fuse F308
 With external supply via
X308: Check external
supply voltage (rated
voltage 24 V)
On = supply voltage present -
8 PWR/1.2V Green Off = no supply voltage  Check fuse F17-3
present  Jumper plug X308 pres-
Power for the
CIB_SR ent
 Check fuse F308
 With external supply via
X308: Check external
supply voltage (rated
voltage 24 V)
On = supply voltage present -
9 PWRS/3.3V Green On = power supply present -
Off = no supply voltage  Check fuse F17-3
present  If the LED PWR/3.3V
lights up, exchange the
CCU_SR module
10 STAS2 Orange Off = no supply voltage  Check fuse F17-3
present  If the LED PWR/3.3V
Safety node B
lights up, exchange the
CCU_SR module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Check cabling at X309,
nal) X310, X312. For test pur-
poses, disconnect the
cables at X309, X310, X312
and switch the controller off
and back on again. If the
error recurs, exchange the
module.

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 12 Troubleshooting

Item Designation Color Description Remedy

11 STAS1 Orange Off = no supply voltage  Check fuse F17-3
present  If the LED PWR/3.3V
Safety node A
lights up, exchange the
CCU_SR module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Check cabling at X309,
nal) X310, X312. For test pur-
poses, disconnect the
cables at X309, X310, X312
and switch the controller off
and back on again. If the
error recurs, exchange the
module.
12 FSoE Green Off = not active -
Safety proto- On = operational -
col of the Flashing = fault code (inter- -
EtherCat con- nal)
nection
13 L/A Green  On = physical connec- -
tion
KCB
 Off = no physical con-
14 KSB Green
nection. Network cable
smartPAD_M 100 Mbit
not plugged in.
C Orange
 Flashing = data traffic on
1 Gbit
the line
15 L/A Green
KSB
16 RUN CIB_SR Green On = operational (normal -
state)
EtherCat
ATμC I/O Off = Init (after switching on) -
node Flashing at 2.5 Hz = Pre-Op -
(intermediate state on
startup)
Single signal = Safe Op -
10 Hz = boot (for firmware -
update)
17 STA1 Orange Off = no supply voltage  Check fuse F17-3
(CIB_SR) present  If the LED PWR/3.3V
μC I/O node lights up, exchange the
CCU_SR module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Exchange CCU_SR module
nal)

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 KR C4 smallsize-2

Item Designation Color Description Remedy

18 STA2 Orange Off = no supply voltage  Check infeed at X1
present  If the LED PWR/3.3V
FPGA node
lights up, exchange the
CCU_SR module
Flashing at 1 Hz = normal
state
Flashing at 10 Hz = boot
phase
Flashing = fault code (inter- Exchange CCU_SR module
nal)
19 27 V Green Off = no supply voltage Check infeed at X1 (rated
present voltage 27.1 V)
Voltage, main
power supply On = power supply present -
unit, without
battery
backup
20 PS1 Green Off = no supply voltage  Check infeed at X1 (rat-
present ed voltage 27.1 V)
Voltage,
Power Sup-  Drive bus switched off
ply 1 (short (BusPowerOff state)
battery On = power supply present -
backup)
21 PS2 Green Off = no supply voltage  Check infeed at X1.
present  Controller in Sleep state
Voltage,
Power Sup- On = power supply present -
ply 2 (medium
battery
backup)
22 PS3 Green Off = no supply voltage On = power supply present
present
Voltage,
Power Sup- On = power supply present -
ply 3 (long
battery
backup)
23 STA1 Orange Off = no supply voltage  Check infeed at X1
(PMB_SR) present  If the LED PWR/5V lights
μC USB up, exchange the
CCU_SR module
Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- Exchange CCU_SR module
nal)
24 PWR/5V Green Off = no supply voltage Check infeed at X1 (rated
present voltage 27.1 V)
Power supply
for PMB_SR Flashing at 1 Hz = normal -
state
Flashing at 10 Hz = boot -
phase
Flashing = fault code (inter- -
nal)

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 12 Troubleshooting

Item Designation Color Description Remedy

25 - - Not used --
26 - - Not used
27 Fuse LEDs Red On = fuse defective Exchange defective fuse
The LEDs Off = fuse OK -
indicate the
status of the
fuses.

12.2 Fuses on the Cabinet Control Unit, Small Robot

Overview
A defective fuse is indicated by a red LED next to the fuse. Once the
cause of the fault has been eliminated, defective fuses must be re-
placed with fuses with the value specified in the operating instructions
or printed on the module.

Fig. 12-2: Arrangement of the fuses

Item Designation Description Fusing

1 F306 smartPAD power supply 2A
2 F302 I/O board power supply 5A
(optional)
3 F3-1 KPP_SR and KSP_SR brakes 15 A
without battery backup
4 F5-1 24 V without battery backup, 15 A
for options
5 F4-1 KPC with battery backup 10 A
6 F307 UL lamp (optional) 2A
7 F4-2 24 V with battery backup, for 2A
fans
8 F22 24 V without battery backup, 7.5 A
for options
9 F5-2 24 V with battery backup, for 7.5 A
options

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 KR C4 smallsize-2

Item Designation Description Fusing

10 F3-2 KPP_SR and KSP_SR logic 7.5 A
with battery backup
11 F17-2 Inputs CCU_SR 2A
12 F17-4 Safe inputs and relays 2A
CCU_SR
13 F17-1 Contactor outputs 1 … 4 5A
CCU_SR
14 F17-3 Logic CCU_SR 2A
15 F14 External fans (optional) 7.5 A
16 F6 I/O board power supply 7.5 A
(optional)
17 F21 RDC power supply 3A
18 F305 Battery infeed 15 A
19 F301 24 V without battery backup, 10 A
for options
20 F15 Power supply unit fan 2A
21 F308 External power supply 7.5 A

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 13 Decommissioning, storage and dispos...

13 Decommissioning, storage and disposal

13.1 Decommissioning
s

Description This section describes all the work required for decommissioning the robot
controller if the robot controller is to be removed from the system. After decom-
missioning, it is prepared for storage or for transportation to a different loca-
tion.
Following its removal, the robot controller may only be transported with lifting
tackle and a fork lift truck or pallet truck.

Precondition  The removal site must be accessible with a crane or with a fork lift truck for
transportation.
 The crane and fork lift truck have an adequate carrying capacity.
 There is no hazard posed by system components.

Procedure 1. Release and unplug all peripheral connections.

2. Release and unplug the motor cable and control cable connectors.
3. Disconnect the ground conductor.
4. Prepare the robot controller for storage.

13.2 Storage

Precondition If the robot controller is to be put into long-term storage, the following points
must be observed:
 The place of storage must be as dry and dust-free as possible.
 Avoid temperature fluctuations.
 Avoid wind and drafts.
 Avoid condensation.
 Observe and comply with the permissible temperature ranges for storage.
 Select a storage location in which the packaging materials cannot be dam-
aged.
 Only store the robot controller indoors.

Procedure 1. Clean robot controller. No dirt may remain on or in the robot controller.
2. Inspect the robot controller, both internally and externally, for damage.
3. Remove batteries and store in accordance with the manufacturer’s instruc-
tions.
4. Remove any foreign bodies.
5. Remove any corrosion expertly.
6. Attach all covers to the robot controller and check that the seals are cor-
rectly in place.
7. Seal off electrical connections with suitable covers.
8. Cover the robot controller with plastic film and seal it against dust.
If necessary, add a desiccant beneath the sheeting.

13.3 Disposal

When the robot controller reaches the end of its useful life, it can be disman-
tled, and the materials can be disposed of properly by type.

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 KR C4 smallsize-2

The following table provides an overview of the materials used in the robot
controller. Some of the plastic components are marked with a material desig-
nation and must be disposed of accordingly.

As the end user, the customer is legally required to return depleted

batteries. Used batteries can be returned to the vendor or brought to
the designated collection points (e.g. in communal refuse collection
facilities or commercial centers) free of charge. The batteries can also be
sent to the vendor by post.
The following symbols can be found on the batteries:
 Crossed-out garbage can: battery must not be disposed of with ordinary
household refuse.

 Pb: battery contains more than 0.004 lead by weight.

 Cd: battery contains more than 0.002 cadmium by weight.
 Hg: battery contains more than 0.0005 mercury by weight.

Subassembly, com-
Material, designation Note
ponent
Steel Screws and washers, -
robot controller hous-
ing
PUR Cable sheaths -
ETFE Flexible tube -
Copper Electrical cables, wires -
EPDM Seals and covers -
CuZn (gold-plated) Connectors, contacts Dispose of without dis-
mantling
Steel (ST 52-3) Allen screws, washers -
PE Cable straps -
Electrical components Bus modules, boards, Dispose of as electri-
sensors cal scrap without dis-
assembling

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 14 KUKA Service

14
4
KUKA Service
A

14.1 Requesting support

v

Introduction This documentation provides information on operation and operator control,

and provides assistance with troubleshooting. For further assistance, please
contact your local KUKA subsidiary.

Information The following information is required for processing a support request:

 Description of the problem, including information about the duration and
frequency of the fault
 As comprehensive information as possible about the hardware and soft-
ware components of the overall system
The following list gives an indication of the information which is relevant in
many cases:
 Model and serial number of the kinematic system, e.g. the manipulator
 Model and serial number of the controller
 Model and serial number of the energy supply system
 Designation and version of the system software
 Designations and versions of other software components or modifica-
tions
 Diagnostic package KRCDiag
Additionally for KUKA Sunrise: Existing projects including applications
For versions of KUKA System Software older than V8: Archive of the
software (KRCDiag is not yet available here.)
 Application used
 External axes used

14.2 KUKA Customer Support

Availability KUKA Customer Support is available in many countries. Please do not hesi-
tate to contact us if you have any questions.

Argentina Ruben Costantini S.A. (Agency)

Luis Angel Huergo 13 20
Parque Industrial
2400 San Francisco (CBA)
Argentina
Tel. +54 3564 421033
Fax +54 3564 428877
[email protected]

Australia KUKA Robotics Australia Pty Ltd

45 Fennell Street
Port Melbourne VIC 3207
Australia
Tel. +61 3 9939 9656
[email protected]
www.kuka-robotics.com.au

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 KR C4 smallsize-2

Belgium KUKA Automatisering + Robots N.V.

Centrum Zuid 1031
3530 Houthalen
Belgium
Tel. +32 11 516160
Fax +32 11 526794
[email protected]
www.kuka.be

Brazil KUKA Roboter do Brasil Ltda.

Travessa Claudio Armando, nº 171
Bloco 5 - Galpões 51/52
Bairro Assunção
CEP 09861-7630 São Bernardo do Campo - SP
Brazil
Tel. +55 11 4942-8299
Fax +55 11 2201-7883
[email protected]
www.kuka-roboter.com.br

Chile Robotec S.A. (Agency)

Santiago de Chile
Chile
Tel. +56 2 331-5951
Fax +56 2 331-5952
[email protected]
www.robotec.cl

China KUKA Robotics China Co., Ltd.

No. 889 Kungang Road
Xiaokunshan Town
Songjiang District
201614 Shanghai
P. R. China
Tel. +86 21 5707 2688
Fax +86 21 5707 2603
[email protected]
www.kuka-robotics.com

Germany KUKA Deutschland GmbH

Zugspitzstr. 140
86165 Augsburg
Germany
Tel. +49 821 797-1926
Fax +49 821 797-41 1926
[email protected]
www.kuka.com

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 14 KUKA Service

France KUKA Automatisme + Robotique SAS

Techvallée
6, Avenue du Parc
91140 Villebon S/Yvette
France
Tel. +33 1 6931660-0
Fax +33 1 6931660-1
[email protected]
www.kuka.fr

India KUKA Robotics India Pvt. Ltd.

Office Number-7, German Centre,
Level 12, Building No. - 9B
DLF Cyber City Phase III
122 002 Gurgaon
Haryana
India
Tel. +91 124 4635774
Fax +91 124 4635773
[email protected]
www.kuka.in

Italy KUKA Roboter Italia S.p.A.

Via Pavia 9/a - int.6
10098 Rivoli (TO)
Italy
Tel. +39 011 959-5013
Fax +39 011 959-5141
[email protected]
www.kuka.it

Japan KUKA Japan K.K.

YBP Technical Center
134 Godo-cho, Hodogaya-ku
Yokohama, Kanagawa
240 0005
Japan
Tel. +81 45 744 7531
Fax +81 45 744 7541
[email protected]

Canada KUKA Robotics Canada Ltd.

6710 Maritz Drive - Unit 4
Mississauga
L5W 0A1
Ontario
Canada
Tel. +1 905 670-8600
Fax +1 905 670-8604
[email protected]
www.kuka-robotics.com/canada

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 KR C4 smallsize-2

Korea KUKA Robotics Korea Co. Ltd.

RIT Center 306, Gyeonggi Technopark
1271-11 Sa 3-dong, Sangnok-gu
Ansan City, Gyeonggi Do
426-901
Korea
Tel. +82 31 501-1451
Fax +82 31 501-1461
[email protected]

Malaysia KUKA Robot Automation (M) Sdn Bhd

South East Asia Regional Office
No. 7, Jalan TPP 6/6
Taman Perindustrian Puchong
47100 Puchong
Selangor
Malaysia
Tel. +60 (03) 8063-1792
Fax +60 (03) 8060-7386
[email protected]

Mexico KUKA de México S. de R.L. de C.V.

Progreso #8
Col. Centro Industrial Puente de Vigas
Tlalnepantla de Baz
54020 Estado de México
Mexico
Tel. +52 55 5203-8407
Fax +52 55 5203-8148
[email protected]
www.kuka-robotics.com/mexico

Norway KUKA Sveiseanlegg + Roboter

Sentrumsvegen 5
2867 Hov
Norway
Tel. +47 61 18 91 30
Fax +47 61 18 62 00
[email protected]

Austria KUKA Roboter CEE GmbH

Gruberstraße 2-4
4020 Linz
Austria
Tel. +43 7 32 78 47 52
Fax +43 7 32 79 38 80
[email protected]
www.kuka.at

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 14 KUKA Service

Poland KUKA Roboter CEE GmbH Poland

Spółka z ograniczoną odpowiedzialnością
Oddział w Polsce
Ul. Porcelanowa 10
40-246 Katowice
Poland
Tel. +48 327 30 32 13 or -14
Fax +48 327 30 32 26
[email protected]

Portugal KUKA Robots IBÉRICA, S.A.

Rua do Alto da Guerra n° 50
Armazém 04
2910 011 Setúbal
Portugal
Tel. +351 265 729 780
Fax +351 265 729 782
[email protected]
www.kuka.com

Russia KUKA Russia OOO

1-y Nagatinskiy pr-d, 2
117105 Moskau
Russia
Tel. +7 495 665-6241
[email protected]

Sweden KUKA Svetsanläggningar + Robotar AB

A. Odhners gata 15
421 30 Västra Frölunda
Sweden
Tel. +46 31 7266-200
Fax +46 31 7266-201
[email protected]

Switzerland KUKA Roboter Schweiz AG

Industriestr. 9
5432 Neuenhof
Switzerland
Tel. +41 44 74490-90
Fax +41 44 74490-91
[email protected]
www.kuka-roboter.ch

Slovakia KUKA Roboter CEE GmbH

organizačná zložka
Bojnická 3
831 04 Bratislava
Slovakia
Tel. +420 226 212 273
[email protected]

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 KR C4 smallsize-2

Spain KUKA Iberia, S.A.U.

Pol. Industrial
Torrent de la Pastera
Carrer del Bages s/n
08800 Vilanova i la Geltrú (Barcelona)
Spain
Tel. +34 93 8142-353
[email protected]

South Africa Jendamark Automation LTD (Agency)

76a York Road
North End
6000 Port Elizabeth
South Africa
Tel. +27 41 391 4700
Fax +27 41 373 3869
www.jendamark.co.za

Taiwan KUKA Automation Taiwan Co. Ltd.

1F, No. 298 Yangguang ST.,
Nei Hu Dist., Taipei City, Taiwan 114
Taiwan
Tel. +886 2 8978 1188
Fax +886 2 8797 5118
[email protected]

Thailand KUKA (Thailand) Co. Ltd.

No 22/11-12 H-Cape Biz Sector Onnut
Sukhaphiban 2 road, Prawet
Bangkok 10250
Thailand
Tel. +66 (0) 90-940-8950
[email protected]

Czech Republic KUKA Roboter CEE GmbH

organizační složka
Pražská 239
25066 Zdiby
Czech Republic
Tel. +420 226 212 273
[email protected]

Hungary KUKA Robotics Hungaria Kft.

Fö út 140
2335 Taksony
Hungary
Tel. +36 24 501609
Fax +36 24 477031
[email protected]

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 14 KUKA Service

USA KUKA Robotics Corporation

51870 Shelby Parkway
Shelby Township
48315-1787
Michigan
USA
Tel. +1 866 873-5852
Fax +1 866 329-5852
[email protected]
www.kukarobotics.com

UK KUKA Robotics UK Ltd

Great Western Street
Wednesbury West Midlands
WS10 7LL
UK
Tel. +44 121 505 9970
Fax +44 121 505 6589
[email protected]
www.kuka-robotics.co.uk

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 Index

Index
Numbers Control PC, functions 12
2006/42/EU2006 52 Control PC, installing 95
2014/30/EU2014 52 Control PC, removing 94
2014/68/EU2014 52 Control unit 22
95/16/EC 52 Cooling, cabinet 18
Counterbalancing system 50
A
Accessories 29 D
Ambient conditions 21 Danger zone 30
Ambient temperature 21 DC 12
ANSI/RIA R.15.06-2012 53 Declaration of conformity 30
Applied norms and regulations 52 Declaration of incorporation 29, 30
Automatic mode 49 Decommissioning 51, 123
Axis limitation, mechanical 40 defective fuses 121
Axis range 30 Device connection cable 56
Dimensions 24
B Dimensions of boreholes 25
Ballast resistor, exchanging 108 Dimensions, smartPAD holder 26
Ballast resistor, installing 111 Disposal 51, 123
Ballast resistor, removing 110 Drive Configuration 12
Batteries 16 Drive unit 12
Batteries, exchanging 101 Drive unit, exchanging 90
Batteries, installing 103 Drive unit, installing 92
Batteries, removing 102 Drive unit, removing 92
Batteries, storage temperature 21 Dynamic testing 64
Battery discharge protection, reversing 75
Brake defect 42 E
Brake release device 41 EA 8
Braking distance 30 EC declaration of conformity 30
EDS 7
C Electromagnetic compatibility (EMC) 53
Cabinet Control Unit LED display 117 Electromagnetic compatibility, EMC 55
Cabinet Control Unit Small Robot, fuses 121 EMC 7
Cabinet Control Unit, Small Robot 15 EMC Directive 30, 52
Cabinet cooling 18 EMD 7
Cabinet Interface Board, Small Robot 15, 23 EMERGENCY STOP 80
Cable lengths 22, 55 EMERGENCY STOP device 37, 38, 42
CCU_SR 7, 15 EMERGENCY STOP devices to X11 62
CCU_SR functions 15 EMERGENCY STOP wiring example 62
CCU_SR LED display, overview 117 EMERGENCY STOP, external 38, 45
CCU_SR relay outputs, checking 84 EMERGENCY STOP, local 45
CCUsr, exchanging 111 EN 60204-12006/A12009 53
CCUsr, installing 114 EN 61000-6-22005 53
CCUsr, removing 112 EN 61000-6-42007 + A12011 53
CE mark 30 EN 614-12006+A12009 53
Charge 16 EN ISO 10218-12011 53
CIB_SR 7, 23 EN ISO 121002010 53
CIB_SR inputs 23 EN ISO 13849-12015 52
CIB_SR outputs 23 EN ISO 13849-22012 52
CIP Safety 7 EN ISO 138502015 52
Cleaning work 50 Enabling device 38, 42
Connecting cables 29 Enabling device, external 39
Connecting cables, connecting 73 Enabling switch 81
Connection conditions, planning 55 Enabling switch, external, X11 61
Connection manager 80 Enabling switches 38
Control PC 12 Environmental conditions 21
Control PC components, exchanging 93 Equipotential bonding 68
Control PC, exchanging 93 Exchanging devices 76

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 KR C4 smallsize-2

Exhaustive discharge, battery 22 KUKA smartPAD 22, 31, 79

External axes 29, 32 KUKA smartPAD, X19 66
External enabling switch, function 62 KUKA System Bus, devices 17
External fan, exchanging 87
External fan, installing 89 L
External fan, removing 88 Labeling 41
Liability 29
F Linear unit 29
Faults 43 List of abbreviations 7
Filter mats 18 Load voltage contactor, checking 68
Floor mounting 25 Load, mechanical 22
Function test 44 Low Voltage Directive 30
Low-voltage power supply 16
G Low-voltage power supply unit, exchanging 103
General safety measures 42 Low-voltage power supply unit, installing 105
Glossary 7 Low-voltage power supply unit, removing 104
Ground leakage current 21
M
H Machine data 45
Hazardous substances 50 Machinery Directive 30, 52
Mains filter, exchanging 106
I Mains filter, installing 108
Identification plate 81 Mains filter, removing 107
Industrial robot 29 Mains frequency 21
Installation compartment, overview 18 Maintenance 49, 83
Installation compartment, technical data 24 Maintenance symbols 83
Installation conditions 25 Manipulator 8, 29, 31
Intended use 9, 29 Manual mode 48
Interfaces 56 Material designation 124
Interfaces, motherboard D3236-K 13 Mechanical end stops 40
Interfaces, motherboard D3445-K 14 Minimum clearances 25
Interfaces, standard 57 Mode selector switch 80
Introduction 7 Monitoring, physical safeguards 36
Monitoring, velocity 39
J Motherboard battery, exchange 98
Jog keys 80 Motherboard D3236-K 13, 14
Jog mode 39, 42 Motherboard D3445-K 14, 15
Motherboard, exchanging 98
K Motor cable, data cable 56
KCB 7 Motor connector X20 57
KCB, devices 17
KEB 7 O
KEB, devices 18 Operation 79
KEI 7 Operator safety 34, 36, 42
Keyboard 80 Operators 33
Keyboard key 80 Options 29
KLI 8 Outer dimensions 24
KOI 8 Overload 42
KONI 8 Overview, components 11
KPC 8
KPP_SR 8 P
KRL 8 Panic position 38
KSB 8 PC fan 96
KSB, devices 17 PC fan, installing 97
KSI 8 PC fan, removing 96
KSP_SR 8 PE, equipotential bonding 68
KSS 8 Performance level 69
KUKA Controller Bus devices 17 Performance Level 35
KUKA Customer Support 125 Peripheral cables 56
KUKA Extension Bus, devices 18 Peripheral contactor 47
KUKA Service 125 Personnel 32

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 Index

PFH values 69 Service life 31

PL 69 Short circuit current rating 21
Planning 55 SIB wiring 58
Plant integrator 32 SIB, safe input 63
Plates and labels 26 SIB, safe output 65
PMB 8 Signal “Peri enabled” 61
Positioner 29 Simulation 49
Power failure 16 Single point of control 51
Power Management Board, Small Robot 15 Slot assignment, motherboard D3236 14
Power supply connection X1 Harting connector Slot assignment, motherboard D3445-K 15
56, 75 smartPAD 31, 43, 79
Power supply connection, technical data 21 smartPAD cable 56
Power supply with battery backup 16 smartPAD cable extensions 22, 55
Power supply without battery backup 16 Software 29
Power switched off 16 Software limit switches 40, 42
Pressure Equipment Directive 50, 52 Space for integration of customer options, over-
Preventive maintenance work 50 view 18
Procurement of spare parts 87 Space for integration of customer options,
Product description 11 technical data 24
Protective equipment 39 Space Mouse 80
Purpose 9 SPOC 51
SSD hard drive, exchanging 98
R SSD hard drive, installing 100
Rated connected load 21 SSD hard drive, removing 99
Rated supply voltage 21 Start backwards key 80
RDC 8 Start key 80, 81
Reaction distance 30 Start-up 44, 73
Recommissioning 44, 73 Start-up mode 47, 76
Release device 40 Status keys 80
Repair 49, 87 STOP 0 30, 31
Resolver cable, length difference 23, 56 STOP 1 30, 32
Robot controller 29 STOP 2 30, 32
Robot controller, cleaning 85 Stop category 0 31
Robot controller, installing 73 Stop category 1 32
Stop category 2 32
S Stop category 1, Drive Ramp Stop 32
Safe operational stop 31, 39 STOP key 80
Safeguard to X11 62 Stop reactions 34
Safeguards, external 41 STOP 1 - DRS 32
Safety 29 Stopping distance 30, 33
Safety controller 35 Storage 51, 123
Safety functions 34, 42 Storage, temperature 21
Safety functions, overview 34 Support request 125
Safety gate, wiring example 63 Switching on the robot controller 78
Safety instructions 7 System configuration, modifying 76
Safety interface X11, description 58 System impedance 21
Safety interface, overview 58 System integrator 30, 32, 33
Safety interface, X11 59
Safety of machinery 52, 53 T
Safety options 31 T1 (operating mode) 32
Safety STOP 0 31 T2 (operating mode) 32
Safety STOP 1 31 Target group 9
Safety STOP 2 31 Teach pendant 29
Safety STOP 0 31 Technical data 21
Safety STOP 1 31 Temperatures 21
Safety STOP 2 31 Terms 7
Safety stop, external 39 Terms used, safety 30
Safety zone 31, 33 Test output A 59, 61
Safety, general 29 Test output B 59, 62
SATA connections 8 Tolerance of rated supply voltage 21
Selecting the operating mode 34, 35 Touch screen 79

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 KR C4 smallsize-2

Training 9
Transient limiter, description 19
Transportation 43, 71
Transportation, lifting tackle 71
Transportation, pallet truck 72
Transportation, set of rollers 72
Troubleshooting 117
Turn-tilt table 29

U
US2 47
US2 function, checking 68
USB 8
USB connection 81
Use, contrary to intended use 29
Use, improper 29
User 30, 32

V
Velocity monitoring 39
Vibration excitation 22
Vibration resistance 22

W
Warnings 7
Workspace 30, 33

X
X11, contact diagram 59
X11, enabling switch 61
X11, safety interface 59
X19, KUKA smartPAD 66
X20, motor connector 57
X21 US2, RDC interface 67
X21, RDC interface 66

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